Toyota 5FBE10-18 - Service Manual

FOREWORD
This manual covers the service procedures of the TOYOTA BATTERY

FORKLIFT 5FBE10-18 Series. Please use this manual for providing
quick, correct servicing of the corresponding forklift models.
This manual deals with the above models as of February 1993. Please
understand that disagreement can take place between the descriptions
in the manual and actual vehicles due to change in design and specifi-
cations. Any change or modifications thereafter will be informed by
Toyota Industrial Vehicles’ Parts & Service News.
TOYOTA MOTOR CORPORATION

0-2
EXTERIOR VIEWS
0-3
VEHICLE MODEL
*: 36 V is provided for UL specification.

FRAME NUMBER
0-4
HOW TO READ THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with a photo or illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, fol-
lowed by explanation of cautions and notes summarized as point operations.
Example of description in pattern B
DISASSEMBLY- INSPECTION - REASSEMBLY Tightening torque unit T = N m (kgf-cm)[ft-lb]
If a place or part be indi-

cated directly, the part name is
described on the either side of
the illustration.
Example: 1 Piping
T=46-09~48.05
(470~490)
[34.00~35.45]
Disassembly Procedure
1 Remove the cover. [Point 1]
2 Remove the bush [Point 2] Operation explained later
3 Remove the gear.
Point operations Explanation of key point for operation with an illustration

[Point 1]
Disassembly: Put a match mark when removing the pump cover.
[Point 2]
Inspection: Measure the bush inside diameter.
Bush inside diameter limit: 19.12 mm (0.7528 in)
0-5
How to read components figures (Example)

The components f igure use the illustra-
tion in the parts catalog for the vehicle 3201
model. Please refer to the c atalog for
checking the part name.
FIG number in parts catalog
The number at the right shoulder of each
components figure indicates the Fig.
number in the parts catalog.
Matters omitted in this manual

This manual omits description of the following jobs, but perform them in actual operation:
Cleaning and washing of removed parts as required
visual inspection (Partially described)
‘
TERMINOLOGY
Caution:
Important matters of which negligence may cause accidents. Be sure to observe them.
Note:
Important items of which negligence may cause accidents or matters in operation procedure re-
quiring special attention.
Standard: Values showing allowable range in inspection and adjustment.

Limit: Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATIONS
0-6
LIST OF ABBREVIATIONS AND SYMBOLS

0-7
OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in
load capacity.
(3) Always disconnect the battery plugs before the inspection or servicing of electrical parts.
2. Tactful operation
(1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pres-
sure gauge, etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the
parts neatly to prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools
and operate in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packings and O-rings with new ones each time of disassembly.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolt and nuts. Observe the specified tightening torque at the time of reassembly.
If no tightening torque is specified, tighten the bolt or nut according to the standard tightening
torque table.
3. Grasping the troule state

When a trouble occurs, do not attempt immediate disassembly or replacement but first check if
the trouble requires disassembly or replacement for remedying.
0-8
CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively ac-
cording to the purpose of measurement.
‘
Analog type: This type is convenient for observing movement during operation, but the measured
value should only be used for reference or rough judgement.
Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or move-
ment.
Difference in measurement results with the digital type and analog type
The result may be different between measurements with the analog type and digital type. Al-
ways use a circuit tester according to its operation manual. Cautions when the polarities are dif-
ferent between the analog type and digital type are described below.
Circuit tester range: Analog type kohm range Digital type 2 Mohm range
Measurement result example
As seen from the example above, the measurement results with the analog and digital types are re-
verse. In measurement with a digital type circuit tester, therefore, use the tester probes as shown be-
low.
0-9
Difference in result of measurement with circuit tester

The circuit tester power supply voltage depends on the tester type. 1.5V, 3.0V or 6.0V is used.
The resistance of a semiconductor such as a diode varies with the circuit tester power supply
voltage.
The diode characteristics are shown in the figure below.
The resistance values of the same semiconductor mea-

sured with two types of circuit testers having different
power supply voltages are different.
Current
in
forward This manual describes the results of measurement
direction with a circuit tester whose power supply voltage is
3.0 V.
voltage in forward direction (v)
Difference in measurement result by measurement range (analog type)

In the analog type circuit tester, changing the measurement
range switches over the internal circuit to vary the circuit
resistance. Even when the same diode is measured, the
measurement result varies with the measurement range.
Always use the range described in the repair manual

for measurement.
0-10
STANDARD BOLT & NUT TIGHTENING TORQUE
Standard bolt and tightening torques are not indicated.

Judge the standard tightening torque as shown below.
1. Find out the type of the bolt from the list below and then find the bolt tightening torque from the
table.
2. The nut tightening torque can judged from the mating bolt type.
BOLT STRENGTH TYPE IDENTIFICATION METHOD
1. Identification by bolt shape 2. Identification by part No.

0-11
TIGHTENING TORQUE TABLE

0-12
PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
Do not use the precoat bolt as it is in either of the fol-

lowing cases.
After is removed.
When the precoat bolt is moved (loosened or tight-
ened) by tightness check, etc.
Note:
For torque check, use the lower limit of the allowable tight-
ening torque range. If the bolt moves, retighten it according
to the steps below.
Method for reuse of precoat bolts

Wash the bolt and threaded hole. (The threaded hole
must be washed even for replacement of the bolt.)
Perfectly dry the washed parts by air blowing.
Coat the specified seal lock agent to the threaded
portion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces
with clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the
contact surfaces before installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and
tighten the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
0-13
WIRE ROPE SUSPENSION ANGLE LIST
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE Unit: N (ton) [lb]
0-14
COMPONENTS WEIGHT
*: 1993.1 ~ 1994.1
**: 1994.1 ~
0-15
RECOMMENDED LUBRICANTS AND CAPACITIES
45S: Refrigerator specification vehicle

*: For 3000 mm (118 in) maximum fork height
**: For 6000 mm (236 in) maximum fork height
0-16
LUBRICATION CHART
1. Chain I Inspect every 8 hours (daily)

2. Mast strip II Inspect every 40 hours (weekly)
3. Tilt cylinder front pin III Inspect every 170 hours (monthly)
4. Mast support bushing IV Inspect every 1000 hours (6 monthly)
5. Front axle hub V Inspect every 2000 hours (annually)
6. Transmission housing Inspect and service
7.
8.
Reservoir tank
Oil control valve link pin
• Replace
9. Accelerator pedal link 1 MP grease

10. Tilt steering locking mechanism 2 Engine oil
11. Brake pedal link 3 Hypoid gear oil
12. Oil tank 4 Brake fluid
13. Rear wheel bearing 5 Hydraulic oil
14. Rear axle bearing 6 MIL-G-3278-A
15. Steering rack & pinion
16. Limit switch controller
(cold storage models only)
0-17
PERIODIC MAINTENANCE
INSPECTION METHOD
I: Inspection. Repair or replacement if required.

M: Measurement. Repair or adjustment if required.
T : Retightening C: Cleaning L: Lubrication
* : For new vehicle *1: Flaw detector
0-18
0-19
0-20
0-21
0-22
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

1-2
SERVICE STANDARDS
DISPLAY INDICATION
1. The display indicates the remaining battery charge

level in 10 stages. When the remaining charge drops
to the set level or below, the indication flashes the
warn the timing for charging.
2. When the battery is discharged fully (100 %), the

overdischarge alarm function operations as follows:
OVERDISCHARGE ALARM FUNCTION
1. Material handling with traveling becomes impossible.

If simultaneous operation is attempted, priority is
given to traveling and material handling is not ef-
fected. (For prevention of battery from damage by
large current flow)
2. When material handling is attempted, all indicators on

the display flash and the buzzer sounds to alarm over-
discharge.
Note:
Material handling operation becomes impossible on the ve-
hicle with chopperless material handling circuit.
For thirty seconds after the key switch is turned on, how-
ever, material handling operation can be performed.
1-3
BATTERY COMPARTMENT & MINIMUM WEIGHT REQUIRED
When purchasing the battery locally, adjust its weight to satisfy the minimum required weight by re-
ferring to the table below. Always use a case allowing fixation of the battery stopper.
1-4
TROUBLESHOOTING
1-5
BATTERY ASSY
REMOVAL INSTALLATION
Removal Procedure
1 Disconnect the battery plug.
2 Remove the battery hood catch.
3 Open the battery hood.
4 Remove the battery stopper.
5 Remove the battery ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.

1-6
GS INSPECTION
1. Electrolyte level inspection
GS battery:
Open the cap and add distilled water if the white line
on the red float is invisible. Add water until the white
line on the float appears and stop addition there be-
cause further addition until the contact between the
float and stopper results in overfilling.
YUASA battery:
Open the cap and add distilled water if the ring of the
red float is dropped. Add water until the float ring
comes into contact with the top portion.
YUASA
As the level gauge is provided on the side surface of

the battery case, the electrolyte level can generally be
checked at a glance. However, periodically inspect the
level by opening the cap.
The green indicator of the level gauge is lit to indicate
activation of the level gauge sensor, and the red indi-
cator flashes to indicate the necessity of water addi-
tion.
Caution:
Never change the mounting position of the plug with
sensor.
Note:
The electrolyte consumption can be calculated by the following equation:
Consumption (CC) = 5 hour rating capacity x 0.0336 x number of cells x charging frequency
2. Electrolyte inspection
(1) The battery electrolyte should be colorless and
transparent in normal state. Check turbidity, etc. at
the time of specific gravity inspection.
If clear confirmation is impossible, put in a beaker
for inspection.
1-7
3. Inspection of electrolyte specific gravity

Use a hydrometer and measure the specific gravity
of the electrolyte
Specific gravity in fully charged state:

1.280 (at 20 C)
Specific gravity in fully discharged state:
1.150 (at 20 C)
The specific gravity of the electrolyte is expressed
by the value at 20 C as the standard.
Specific gravity conversion equation
S = St + 0.0007 (t-20)
S: Specific gravity at 20 C
St: Specific gravity at t C
t: Temperature at the time of measurement
*How to use the hydrometer

1 Insert the nozzle of the hydrometer into the wa-
ter supply port and suck the electrolyte into the
outer cylinder.
2 Let the hydrometer in the outer cylinder float
correctly without contact with the top, bottom
and side wall of the outer cylinder, and read the
graduation at the electrolyte surface as shown
at left after disappearance of bubbles in the
sucked electrolyte.
3 After the measurement wash outside and in-
side of the hydrometer with clear water and
wipe thoroughly with clean cloth for storage.
4. Insulation resistance inspection

Use an insulation resistance meter (megger) and mea-
sure the resistance between the battery and battery
case.
Insulation resistance: 1 M or more
Note:
If the insulation resistance is less than 1 M, remove
the battery from the vehicle and wash it with water.
Dry the battery case roughly, and measure the insu-
lation resistance again. Install the battery on the ve-
hicle after checking that the insulation resistance is
1 M or more.
1-8
* Battery control table

Prepare the control table for each battery to record and retain the inspection result.
2-2
MCS-IIIA CONTROLLER
GENERAL
The 5FBE series is provided with the diagnostic (self-diagnosis) function for automatically detecting
any abnormality in the main traveling/material handling circuit, operating system such as the acceler-
ator and sensors to sound the buzzer (bleep, bleep) and to display the abnormal portion by the corre-
sponding error code on the multi-display.
At the same time, such an action as traveling stop, material handling stop or traveling speed restriction
is taken to ensure safety.
When the display is set to the analyzer (fault analysis) mode, defect detection and functional check of
the main drive/material handling circuit, operating systems, and sensors are performed.
See the Multi-display section (page 3-2) for the diagnosis. See the Multi-display section (page 3-7) for
the analyzer.
Control Panel ASSY Contactor Panel ASSY

2-3
SPECIFICATIONS
*: 36V specification
*: The PS transistor and diode are integrated.
*: UL specification (36V/48V)
2-4
COMPONENTS
Control panel
2401
2-5
Resistor panel
2401
2401-147
2-6
Control panel W/material handling chopper (OPT)
2401
2-7
Contactor panel
2402
2-8
MF MR contactor
2403
MP contactor
2403
2-9
CONTROL PANEL REMOVAL INSTALLATION
1 Battery plug
5 Connector
6 Wiring
Removal Procedure
2 Remove the side panel LH.
3 Remove the side panel under cover.
4 Remove the control panel cover.
5 Disconnect the connector.
6 Disconnect the wiring.
7 Remove the control panel.
Note:
Check insufficient cable tightening or cable tightening failure before inserting the battery plug. If loose,
the control panel elements may be damaged.
2-10
CONTACTOR PANEL REMOVAL INSTALLATION
Removal Procedure
2 Remove the toe board.
3 Remove the side panel LH.
4 Remove the side panel under cover.
5 Disconnect the wiring.
6 Remove the contactor panel.
Note:
Check insufficient cable tightening or cable tightening failure before inserting the battery plug.
2-11
INSPECTION
Some parts can be inspected after removal from the vehicle while others can only be inspected on the
vehicle.
As the CPU board and DC-SD boards require battery voltage application, they must be inspected while
being mounted on the vehicle. (Use SST 09240-12240-71.)
Inspection after control panel removal from the vehicle is mainly explained here.
1. Insulation resistance measurement (Always inspect before starting control panel inspection.)
(1) Disconnect the battery plug and measure the insulation resistance between the battery plug
and body.
2-12
2. CAD (drive circuit absorber capacitor) and CAP (material handling circuit absorber capacitor)
(OPT)
(1) Inspection method
Disconnect the wiring of CAD and CAP after discharging the CAD and CAP with a resistor of
about 100 Ω .
Standard
CAD CAP
3. TM (drive circuit main transistor). TMP (pump circuit main transistor)

Disconnect wiring from each of TM TMP
If any TM or TMP is found abnormal in inspection replace them (all TMs or all TMPs) as a set.
TM TMP
2-13
3-1. DRD (Direction of Reverse Conductive Diode)

Remove the DRD.
4. DF1 (flywheel diode No.1)

Disconnect the wiring from DF1
2-14
5. DF2R-DF2L (flywheel diode No.2)

Disconnect the wiring from DF2R-DF2L
6. DF3 (flywheel diode No.3 in panel with pump chopper)

(1)
7. DAD (drive circuit absorber diode) DAP (pump circuit absorber diode)
Disconnect the wiring from DAD DAP.
DAD DAP
8. MF R . MFL (forward contactors) MR R. MR L (reverse contactors) MP (material handling pump con-

tactor)
(1) Measure the coil resistance of each of MFR.MFL. MRR.MRL.MP.
2-17
9. RAD (drive circuit absorber resistor) RAP (pump circuit absorber resistor)
Battery removal
Disconnect the wiring from RAD RAP (RAD: CN118 RAP: CN119).
RAD RAP
When inspecting with the battery installed, disconnect the CN1 17 connector.
CN 17 ( Main harness side

2-18
10. CPU board DC-SD board

If the trouble cause is judged to be in the CPU board or DC-SD board, apply the battery voltage,
install SST09240-12240-71, and measure the applied voltage and resistance at each connector.
Caution:
Always disconnect the battery plug before removing or installing the CPU board or DC-SD board.
Note:
When replacing the CPU board or DC-SD board judged to be causing the trouble as a result of trou-
bleshooting, always measure the applied voltage and resistance at related portions before replace-
ment.
Use SST 09240-12240-71 for the measurement.
(1) SST connection method

1 Turn the key switch to OFF.
3 Disconnect the CPU board DC-SD board connectors (CN101 to CN107 CN111 CN112).
4 Connect the SST.
2-19
(2) Lists of measurement methods and standards

1 Explanation on list format
2 Lists
CN101 connector Basic conditions (battery plug ON ·SWKY ON)
2-20
CN102 connector: Basic conditions (Battery plug ON ·SWKY ON)

2-21
CN103 connector: Basic conditions (Battery plug ON · SWKY ON)

2-22

2-23
CN105 Connector: Basic conditions (Battery plug ON · SWKY ON)

2-24
CN106 Connector: Basic conditions (Battery plug ON · SW KY ON)

2-25

2-26

2-27
CN112 connector: Basic conditions (Battery plug ON ·

2-28
11. Display
If the cause of a trouble is judged to exist in the display, apply the battery voltage and measure
the voltage at the connector.
CN120 connector basic condition (battery plug ON)

2-29
DISASSEMBLY
The control panel is overhauled infrequently. Defective part replacement according to the cause of the
trouble by inspection is performed in most cases. Please perform correct operation by referring to the
component parts drawing, assembly drawing and internal connection diagram.
Cautions for Parts Replacement
• Tighten the bar and harness set nuts and screws to the specified torques.
Looseness or insufficient tightening will cause other troubles.
• When disconnecting a bar or harness, take a memo on the mounting position or attach a tag indi-
cating the mounting position. At the time of reassembly, prevent incorrect installation or wiring by
referring to the memo or tag. Incorrect installation or wrong wiring will cause other troubles.
• Always coat silicone grease on parts which have been coated with silicone grease. Omission of
coating may cause overheating.
• After reassembly, check no contact of the bars and cables at other than the contact portions. Before
installation on the vehicle, check continuity at points with a circuit tester. (See page 2-34 for the
inspection points with the circuit tester.)
2-30
REASSEMBLY
Control panel assembly drawing (STD)

2-31
Control panel assembly drawing (with pump chopper)

2-32
Contactor panel assembly drawing

2-33
PANEL PARTS TIGHTENING TORQUE
(Control panel)
(Control panel)
(For power steering)

2-34
CONTINUITY CHECK WITH CIRCUIT TESTER
Inspection method Positive (+) probe: Red probe Negative (-) probe: Black probe
* In the initial stage, the pointer indicates the capacitor characteristic because the capacitor is
charged. Capacitor characteristic: The pointer deflects to 0 Ω and returns to ∞ Ω then.
2-36
OCL (OVERCURRENT LIMIT) VALUES
Drive circuit OCL value measurement

(1) Lock the front and rear wheels with the vehicle in the traveling state. Connect the ammeter and
shunt as illustrated below and measure the drive motor lock current.
Standard OCL value:

48 V vehicle: 460 A
36 V vehicle: 610 60 A
Ammeter:
50 mV, 750 A
Shunt:
50 mV, 750 A
(2) Judgment method If the measured OCL value is not within the standard range, the current sen-
sor (CS) or CPU board may be defective. Make judgment as follows:
1 Jack up the vehicle and support the front and rear sides of the frame with wooden blocks.
2 Measure the output voltage of the current sensor. (Measured offset voltage value: B)
Conditions: Battery plug ON · SWKY ON
Measurement terminals: CN104(9)71 + - CN104(8) 74 -
Standard: Approx. 1.2V
* Use a digital voltmeter for measurement.
3 Operate the accelerator to set the speed to approx. 8 km/h (5 mile/h). Read the ammeter
and measure the current sensor output voltage on the CPU board side at the same time.
(Ammeter reading: A) (Measured current sensor output voltage: C)
Measurement terminals: CN104(9)71 + - CN104(8)74 -
* Use a digital voltmeter for measurement.
4 Calculation
Measured value C - measured value B = D
Convert the calculated value D according to the following equation. (Converted value: E)
1V = 100A
5 Judgment
Compare converted value E with measured value A in step 3 .
The current sensor can be judged normal if the result is within ± 5.
The CPU board may defective if the current sensor is judged normal. Replace the CPU
board in that case.
2-36
2. Pump circuit OCL value measurement

The OCL value of the pump circuit cannot be measured because of the following reason:
In the material handling system the relief valve in the control valve operates at the stroke end of
each cylinder.
The OCL value for the pump circuit is set at a higher level than the current at the relief valve set
pressure.
As relief occurs in the hydraulic circuit before the pump circuit current reaches the OCL valve, the
OCL valve cannot be measured.
2-37
ACCELERATION POTENTIOMETER
ADJUSTMENT
Make adjustment in the state of acceleration potentiometer
w/front toe board.
1. Operate the accelerator pedal and check if the acceler-

ation switch is turned ON and OFF.
Measurement terminals: 51 and 64
Standard
When the pedal is not depressed: ∞
When the pedal is depressed: 0 Ω
2. Acceleration potentionmeter installation adjustment

(1) Insert a 1.5 mm (0.06 in) thickness gauge between
the accelerator link stopper and accelerator bracket.
(2) Temporarily install the potentiometer so that the
switch (SWAC) is set to ON.
(3) Inspect the switch (SW AC) ON and OFF changeover
points.
When 1.0 mm (0.04 in) thickness gauge is inserted:
OFF
When 2.0 mm (0.08 in) thickness gauge is inserted:
ON
(4) After the end of switch ON OFF adjustment, fully
2-38
BRAKE SWITCH STOP LAMP SWITCH

ADJUSTMENT
Adjust protrusion (A) of the brake switch (LSB) and
stop lamp switch (LSST).
A = 26 mm (1.02 in)
After installing LSB and LSST, check ON and OFF.

(1) Operate the brake pedal and check conduction at
each switch connector
Standards
(2) Adjust each switch ON/OFF timing when the brake

pedal is operated. Make adjustment by turning the
adjusting bolt so that each switch is operated when
the brake pedal is depressed by dimension B in the
figure from the free state.
2-39
PARKING BRAKE SWITCH ADJUSTMENT

1. Inspect parking brake switch (SWPB) ON/OFF.
Standard
2. Adjust the SWPB installation state.

(1) Return the lever fully to the stroke end.
(2) With the limit switch pushed to its stroke end to-
ward the lever side, fix the switch by tightening the
switch bracket set bolts 1 and limit switch set
screws 2.
2-40
MATERIAL HANDLING SWITCH

ADJUSTMENT
1. Adjustment the switch (LSL1 LST) ON timing when the

control lever is operated.
(1) Adjust LSL1 LST roller protrusion (A).
Dimension A is a reference value for reassembly.
A = 26 mm (1.02 in)
(2) The switch shall be turned ON at dimension A at the

tip end of the control lever.
Standard
B = 5 20 mm (0.20 0.79 in)
If the standard is not satisfied, make adjustment by

changing the roller protrusion and mounting position.
When pump chopper (OPT) is provided:
2. Adjust the pump chopper switch (LSL2) ON timing.

(1) Adjust LSL2 roller protrusion (C).
C = 26 mm (1.02 in)
(2) Adjust by turning the adjusting bolt so that the

switch (LS S2 ) is turned on when the lift lever is
fulled to 10 ~15 mm (0.39 ~ 0.59 in) before its
stroke end.
2-41
DIRECTION SWITCH
REMOVAL · INSTALLATION
Removal Procedure
1 Remove the steering rear cover.
2 Disconnect the direction switch connector.
3 Remove the steering tilt lever.
4 Remove the steering front cover and display.
5 Remove the direction switch.
2-42
DISASSEMBLY INSPECTION REASSEMBLY
1 Remove the plate.
2 Remove the micro switch base.
3 Remove the micro switch W/wire harness. [Point 1]
4 Remove the cam roller and spring.
5 Remove the direction lever W/knob.
6 Remove the cam.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
2-43
Point Operation
[Point 1]
Reassembly: Install the microswitches in the correct posi-

tions.
Reassembly: When replacing a microswitch, connect the

cables according to the cable colors in the fig-
ure.
Inspection: After assembling the direction switch, check

conduction of each microswitch before install-
ing the direction switch.
2-44
PS CONTROLLER
COMPONENTS
STD (MPS contactor: The MPS contactor is installed on the PS motor.)
2403
2403-07
EHPS
2401
2401-146
2-45
INSPECTION (STD)
1. P22-N1 voltage measurement

Battery plug ON SWKY ON
2. MPS contactor coil conduction measurement

Battery plug OFF SWKY OFF
2-46
REMOVAL INSTALLATION (EHPS)
1 Battery plug
Removal Procedure
2 Remove the side panel.
3 Remove the toe board.
4 Disconnect the wiring connectors.
5 Remove the PS controller.

2-47
EHPS CONTROLLER VOLTAGE MEASUREMENT
When the cause of a trouble is judged to exist in the EHPS controller, measure the battery voltage and
measure the voltage and conduction at the EHPS controller connector.
Measure the battery voltage at the terminal in the PS cont-

roller. (See the illustration.)
Battery plug ON
P21 (TMPS C1 terminal)-N1 (CSPS N1 terminal)
SWKY ON: Battery voltage
SWKY OFF: 0 V
P22 (TMPS C2E1 terminal)-N1 (CSPS N1 terminal)
SWKY ON
When the steering wheel is operated: Approx. 0 V
When the steering wheel is not operated: Battery
voltage
CN27
Measurement terminals
CN27 Connector Basic conditions (Battery plug ON SWKY ON)

2-48
INSPECTION (EHPS)
1. TMPS
Disconnect the wiring from TMPS.
Note:
l When shifting to check C2E1-E2 from G2-E2 short connect G2-E2 to avoid the possibility of conti-
nuity on both directions.
l Never touch to G2 terminal with a naked hand.
2-49
REASSEMBLY (EHPS)
EHPS Control Panel Part Tightening Torques

2-50
STEERING POTENTIO INSTALLATION ADJUSTMENT
1. Jack up the vehicle and support the frame at the front and rear with wooden blocks.
2. Install the steering potentio (VRSP) as illustrated below.
Note:
l When fitting the potentio bolt on the potentio plate, fix the potentio plate with a vise or spanner.
Bring the tip end of the potentio bolt into contact with the flat face of the potentio shaft.
l Carefully operate so as not to pry the potentio shaft.
T = N m (kg-cm) [ft-lb]
3. Adjust the steering sensor neutral position.

(1) Set the battery plug to ON and key switch to ON.
(2) Set the analyzer mode on the display and select test operation mode in category 1, subcategory
2. (See page 3-9 for how to use the analyzer.)
(3) Release the parking brake. Set the direction lever to the forward position and operate the steer-
ing wheel to set the rear wheel to the straight traveling position (neutral position).
(4) Pull the parking brake and return the direction lever to the neutral position.
2-51
(5) Operate the up or down switch on the display to se-

lect monitor code No.7 (steering potentiometer volt-
age).
If the parking brake indicator mark comes on when
monitor code No.7 is selected, it means the correct
neutral position. The adjustment in step (6) below is
unnecessary.
(6) Loosen the steering potentio set screw, and grad-

ually turn the potentio body clockwise or counter-
clockwise until the indicator mark comes on.
Then, tighten the potentio set screw.
Turn the potentio clockwise to increase the po-
tentio voltage.
Turn the potentio counterclockwise to decrease
the potentio voltage.
Note:
The indicator mark comes on when the potentio voltage is
in a range between 2.3 V and 2.4 V.
First, determine the potentio position for a potentio voltage
of 2.3 V. Then turn the potentio slowly clockwise to search
the indicator mark lighting position.
(7) Turn the steering wheel slowly clockwise and

counterclockwise and confirm the following con-
trols are performed.
Forward rotation control, single wheel rotation
control and reverse rotation control.
3-2
DIAGNOSIS
GENERAL
The 5FBE Series has the self diagnostic function, which automatically detects errors in the main drive
and material handling circuits, operation systems such as the accelerator, sensors, etc., and sounds
the buzzer while displaying these errors by corresponding error codes on the multi-display.
At the same time, safe operation is ensured by automatic stop of traveling, stop of material handling
and or traveling speed control.
Depending on the trouble only the error code appears on the multi-display. Although the vehicle may
be operated, make necessary repairs as soon as possible.
The self diagnosis mode may be switched to the analyzer (error analysis) mode, in which failure is de-
tected and, the main drive and material handling circuits, each operation system, sensors, etc. are
checked for functions.
Use these functions fully for early detection and elimination of electrical system troubles.
1. Error code display

The error code appears in part 1 in the illustration,
and the warning sound bleeps. Make repairs soon ac-
cording to the error code displayed by self diagnosis
while referring to “Troubleshooting” in Repair Manual.
3-3
Diagnostic Error Code List
* Can be enabled or disabled by the display mask function (provided only for the vehicle with deadman switch).
3-4
3-5
*2. Only for vehicle with material handling chopper (OPT)

*3. Only for U.S.A. specificaton vehicle
3-6
*4. Only for vehicle with EHPS (OPT)

*5. Only for vehicle with on-vehicle type charger
*6. No alarm sound
3-7
ANALYZER
GENERAL
The 5FBE series has the analyzer for function check and defect detection of the main drive and mate-
rial handling circuits, operating system such as accelerator, and sensors by switching the multidisplay
into the analyzer mode for quick and easy servicing.
Use these functions fully for early solution of troubles in the electrical system.
General Description of Analyzer Functions
The analyzer supports controller system inspection and locating of defective parts by making full use
of the computer function of the MCS-IIIA controller and the communication function between MCS-
IIIA and multidisplay.
(1) Monitoring the history of past errors (diagnosis monitor)
(2) Testing the connections and insulation defects of wiring and connectors (switch input test)
(3) System check with actual travel and material handling operations (test operation)
3-8
Test items by analyzer

3-9
USING THE ANALYZER MODE
Preparation for analyzer mode
Caution:
Before starting analyzer mode operation, always jack
up the frame until the front and rear wheels leave the
ground, support the frame with wooden blocks for sta-
bilization, and bring the fork down to the lowermost
position.
1. Set the battery plug to ON.
2. Set the key switch to ON.
Note:
If diagnosis error code “AF”, “CE”, “CF”, “EE”,
“F1”, “F2” or “F3” is displayed, the analyzer mode
cannot be used.
Switching to the analyzer mode
The multidisplay is generally set to the diagnosis mode.
This display is protected by mask functions to prevent the important internal data from being de-
stroyed by incorrect user operation.
Switching to the analyzer mode, therefore, requires password entry from the switch panel.
1. Primary password entry
Operate the display switch panel according to the se-

quence shown in the illustration.
If not operated within 10 seconds, the mode returns to

the ordinary traveling/material handling mode (diagno-
sis mode).
Keep pressing the switch in the final step for 2 sec-

onds. The intermediate mode screen is displayed.
If the operation is mistaken halfway, set the key

switch to off once and repeat the operation from the
beginning.
Note:
Your finger must be used for the panel switch operation.
If sharpened tools are used instead, it would be a cause of
damage on switch.
2. Intermediate mode display
Transition to the analyzer, hour meter start or MCS-

IIIA tuning mode occurs from this mode.
3. Analyzer mode input
Operate the display switches in the sequence shown in

the illustration.
3-11
4. Analyzer activation
The display changes as illustrated and the analyzer is

activated.
Then the initial display appears.

If the analyzer cannot be activated by the operation
above, turn the key switch OFF once and repeat from
the primary password input again. If not activated by
repeated operation, system abnormality may exist.
5. Initial display
Transition to each analyzer mode occurs from this dis-

play state.
3-12
METHOD FOR SELECTING EACH ITEM
Each item can be selected by adjusting the speedometer display to the corresponding category and
class numbers.
1. Item selection from analyzer activation state (initial display) (Example: 12)
3-13
2. To select another item from one item
(1) To select another class in the same category (Example: 12 13)

3-14
(2) To select an item in a different category (Example: 13 New item)

3-15
3. Ending analyzer mode (transition to diagnosis mode)

3-16
When the switch in step 6 is pressed in step 4 (flashing of “n”), the display returns to 1 (initial
display).
It is also possible to end the analyzer mode by setting the key switch to OFF.
3-17
FUNCTIONAL EXPLANATION OF EACH TEST ITEM
The simple test consists of 35 test items ESY-01 to ESY-35, each with its specific display.
Simple test item selection method
1. Initial display
2. Switch operation method
Press 1 : Proceeding to the next test item

(Ex. ESY01 02)
Press 2 : Returning to the preceding test item

(Ex. ESY02 01)
Press 3 : Repeating the same test item
Press 4 : Ending the simple test (returning to the

class selection display)
3-18
Simple Test Function Map

3-20
Test No.: ESY-01
The following items are checked automatically and the results are displayed:
1 Main drive circuit and main pump circuit check . . . . . . . . . . . . . . . . . . . . . . . . . . CO-EO

2 Drive current sensor and pump current sensor zero point check . . . . . . . . . . . . C1-E1
3 Speed sensor discontinuity detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
1. If the check result is normal, 00 is displayed on the

speedometer.
2. If abnormal, the corresponding error code is displayed

with buzzer sounding.
3. If multiple errors occur, they are displayed sequen-

tially.
Action: Investigate the error position by referring to the

troubleshooting.
Test No.: ESY-02 to 11
Past diagnosis errors are displayed.
ESY-02: Most recent error

-----
-----
ESY-11: Oldest error
1. Select the function by pressing the switch.
(1) ESY-xx is displayed with blinking three times on

the hour meter.
(2) The error occurrence time and error code are dis-
played on the hour meter and speedometer, re-
spectively.

troubleshooting.
3-21
Test No. ESY-12 to 14
The voltage at the voltage input terminal is measured and

displayed.
ESY-12: Voltage at battery terminal (intermediate tap)

ESY-13: Voltage at key switch terminal (intermediate tap)
ESY-14: VBP9 voltage at P9 terminal
1. Select the function by pressing the switch.
(1) ESY-xx is displayed with blinking three times on

the hour meter.
(2) The voltage is displayed on the hour meter.
(3) Measure the input voltage at each terminal with a

multimeter, and check the difference from the dis-
played value.
Standard (See page 2-21.)
VBBT/VBKY: Within ± 1%
VBP9: Within ± 5%
(4) AS the VBKY over 54 V cannot be displayed, con-

dact this check only when it is 54 V or less.
Action: Abnormality of trimmer potentiometer in CPU

Replace the CPU board.
Note:
Never tamper with the trimmer potentiometer.
When the voltage is 0, check the harness.
Test No.: ESY- 15
The potentiometer voltage with satisfaction or dissatisfac-

tion of the specified range and the properness of the corre-
sponding switch ON/OFF state are displayed.
ESY-15: Accel potentiometer (SWAC VRA)
1. Press the switch to select the function.
(1) ESY-15 is displayed with blinking 3 times on the

hour meter.
(2) The potentiometer type and potentiometer volt-

age are displayed on the hour meter.
(3) The speedometer displays whether the potenti-

ometer voltage is within the specified range and
whether the switch on/off state is proper.
Action: Check the potentiometer installation state.

Check the harness.
Replace the potentiometer.
3-22
Test No.: ESY-16
Temperature sensor check
The temperature detected by the thermistor on the CPU board is displayed. The properness of the tem-
perature and voltage range is checked and displayed.

hour meter.
(2) The temperature on the CPU board is displayed on

the hour meter.
(3) The speedometer displays whether the tempera-

ture range is normal and whether the thermistor
voltage is normal.
Actions: Check the ambient temperature of the CPU

board by comparison with the data measured
by the thermometer. Within 5 C.
Test No: ESY-17
Steering potentiometer check
The steering potentiometer voltage is displayed.

hour meter.
(2) The potentiometer type and voltage are displayed

on the hour meter.
(3) The speedometer displays whether the potenti-

ometer voltage is in the specified range or not.
3-23
Contactor closing test
ESY-18: Forward right contactor (MFR) test

ESY-19: Reverse right contactor (MRR) test
ESY-20: Forward left contactor (MFL) test
ESY-21: Reverse left contactor (MRL) test
ESY-22: Pump contactor (MP) test
ESY-23: PS contactor (Mps) test
Press the switch to select the function.
ESY-xx is displayed with blinking three times on

the hour meter.
The contactor code is displayed on the hour
meter.
Visually check closing or opening of each contac-
tor.
Actions: Check welding of the contactor.

Check the resistance of the contactor coil.
Check the voltage at the time of contactor
closing.
(The contactor is defective if it is 30 V or
more.)
Switch ON/OFF and buzzer check
ESY-24: Forward direction switch (DSF)

ESY-25: Reverse direction switch (DSR)
ESY-26: Accelerator switch (SWAC)
ESY-27: Brake switch (LSB)
ESY-28: Speed control switch (SWSC) (Not in US specifi-
cation)
ESY-29: Parking brake limit switch (LSPB)
ESY-30: Lift limit switch 1 (LSL)
ESY-31: Lift limit switch 2 (LSL2) (Only in vehicle with
material handling chopper)
ESY-32: Tilt limit switch (LST)
ESY-33: Deadman limit switch (LSD)
ESY-34: Attachment limit switch (LSATT)
ESY-35: Attachment limit switch 2 (LSATT2)
(1) ESY-xx is indicated with blinking three times on

the hour meter.
(2) The switch code is indicated on the hour meter.
(3) When the selected switch is set to ON, F dis-
played on the hour meter is changed to 0 and the
buzzer sounds.
Actions: Check the switch.

Check the switch harness.
Check the CPU board.
3-24
In the test operation, traveling and/or material handling are possible while monitoring the analog input
value of each sensor.
If a diagnosis error occurs during traveling and/or material handling, the error code is displayed to en-
able very infrequent troubles to be confirmed.
Analog input items to be monitored
3-25
The analog inpThe analog input value is displayed in the test operation.
The error codeThe error code is displayed when an error occurs and is retained until the error clear switch is pressed.
Press the switch to select the function.
The test No. is displayed on the hour meter.
The current value, etc. during the test operation

are displayed on the hour meter.
12 (Category: 1, class: 2) is displayed on the

speedometer in normal state.
If an error occurs, the error code is displayed on

the speedometer and is retained until the error
clear switch is pressed.
Action: Investigate the error position and the part show-

ing an abnormal value by referring to the trouble-
shooting procedure.
Steering potentiometer neutral state check
Select monitor code 7 and set the tire in the neu-

tral position, and confirm that the parking brake
indicator mark is displayed.
If not displayed, adjust the steering potentiometer

until the indicator mark appears. (See page 2-50
for detail.)
Traveling while monitoring the traveling speed value input from the speed sensor is possible during the
test operation.
If a diagnosis error occurs during traveling and/or material handling, the error code is displayed to en-
able very infrequent troubles to be confirmed.
(1) The test No. is displayed on the hour meter.
(2) The traveling speed or speed sensor input data is

displayed on the hour meter.
(3) When an error occurs, the error code is displayed

on the speedometer and is retained until the error
clear switch is pressed.
Action: Investigate the error position and the part show-

ing an abnormal value by referring to the trouble-
shooting procedure.
3-27
Category 2 Class 1 Diagnosis monitor
Past errors (10 items in total) are displayed with the corre-
sponding hour meter readings.
Use this test when the user found an error during operation
but failed in reappearance.
1 Press the switch to select the function
(1) The serial number of error occurrence is displayed

on the battery charge indicator.
(2) The time of error occurrence is displayed on the

hour meter.
(3) The error code is displayed on the speedometer.

troubleshooting procedure.
3-28
Category 3 Class 1 Switch input test : ON/OFF information
The ON/OFF state of every switch is displayed to allow confirmation at a glance.
A level line in the battery charge indicator or a level line in the power control level gauge corresponds
to each switch.
The corresponding position comes on when a switch is ON.
Display and switch table

3-29
1. The corresponding part is lit, when a switch is set to

ON.
Action: If the switch ON/OFF state is different from the

display, check the switch, harness and CPU board
and repair the defective part.
Category 3 Class 2 Switch input test : Buzzer check
The ON/OFF state of each switch is informed by the buzzer.
Uses:
(1) Tuning of limit switch or potentiometer
(2) Switch ON/OFF check in a place where the display is invisible
1. Press the switch to select the switch to be tested.
(1) See page 3-28 “Display and Switch Table” for

the types of switches.
2. Operate the switch and check if the buzzer sounds.
Action: If the switch ON/OFF state differs from the buzzer

indication, check and repair the switch, harness
or CPU board.
3-30
Category 3 Class 3 Switch input test: Momentary interruption test
Memory interruption (open-circuit) in the switch input line

is checked.
1. Set the switch to be checked to ON.
2. Press a switch to match the display with the desired

switch to be checked.

the switch types.
(2) When the buzzer is sounding, stop it by pressing

the stop switch.
3. Shake or apply vibration to the wiring to be checked.
(1) The buzzer sounds if momentary interruption

(opencircuit) occurs.
Action: Repair the switch or harness.
Category 3 Class 4 Switch input test: Short-circuit test
Short-circuit in the switch input line is checked.
1. Set the switch to be checked to OFF.
2. Press the switch to match the display with the desired

switch to be checked.

the switch types.
(2) When the buzzer is sounding, stop it by pressing

the stop switch.
3. Shake or apply vibration to the wiring to be checked.
(1) The buzzer sounds if shortcircuit occurs.
Action: Repair the switch or harness.

3-31
MASK FUNCTIONS
The digital multi-display has built-in mask functions for vehicle maintenance and specification setting
by the service man in addition to the general functions displayed in the owner’s manual for use by gen-
eral users.
To prevent destruction of important internal data by incorrect use of mask functions by the user, the
mask functions are protected by prohibiting use unless the password is input from the switch panel.
The password is described in this manual and repair manual, but is not described in the vehicle owner’s
manual.
Display Mask Functions (1)

Display Mask Functions (2)
The following mask functions are provided for the manager of the user. The dealer should advise the
manager of the user how to operate as required.
3-33
PASSWORD INPUT METHOD
Password list
For items described as start in the processing column (analyzer mode, MCS-IIIA tuning mode, tire diameter con-
stant rewrite mode and option input mode) follow the operation procedure described below after inputting the
secondary password. For any other item, processing automatically ends here upon input of the secondary pass-
word.
Note:
Your finger must be used for the panel switch operation.
If sharpened tools are used instead, it would be a cause of damage on switch.
3-34
1. Hour meter start

The hour meter does not start counting when a new vehicle is delivered. Always start the hour
meter when the vehicle is delivered from the dealer to each user. See the password list for start-
ing the hour meter.
Note:
Once the hour meter is started, it cannot be stopped. Hour meter starting is necessary also after re-
placement of the meter control board ASSY.
2. MCS-IIIA tuning mode

When restriction of the maximum speed or weakening of the plugging braking force is desired,
key in the password and start the MCS-IIIA mode. Then tuning is possible similarly as power con-
trol adjustment.
The 11 items shown below can be adjusted:
Note:
Items marked * 1 are invalid in models without the material handling chopper. (Display appears.)
3-35
MCS-IIIA Tuning mode Initial Level Setting List

3-36
(1) Tuning method
Input the primary password and secondary password.
Primary password Secondary password
When the power control select switch is pressed, the tuning mode is indicated by the
speedometer on the display and the power control level indicates the current tuning
level of the mode.
As the tuning mode is changed sequentially (C1 C2 C3) each time the power con-
trol select switch is pressed, select the desired tuning mode.
Carry out tuning by pressing the level setting (up or down) switch.
To increase the tuning level: Press the up switch.
To decrease the tuning level: Press the down switch.
The tuning level is indicated on the display.
If another item is to be tuned in succession, repeat steps 2 and 3.
Use one of the three methods shown below for returning from the tuning mode.
• Press the hour meter select switch to return to the standard display (speed display).
• Turn the key switch to the OFF position.
• Leave the state unchanged. (Automatic returning to the standard display occurs in 2
minutes if no operation is made.)
3-37
3. Tire diameter coefficient rewriting
The speedometer indication is influenced subtly by the tire type (tire diameter).
Setting for a new vehicle is made according to the tires installed on the vehicle. When tires are
replaced with other tires in a different size (new tires), set the tire diameter constant rewriting.
Also perform this setting when tires are exclusively worn or when special tires are used.
Select any of the three following methods for setting:
Method A: When replaced with new tires in a different size (excluding special tires)
Method B: When replaced with special tires
When the installed tires are worn to make the speedometer indication be felt incorrect.
Method C: When tires are worn to make the speedometer indication be felt incorrect while the
outside diameter of the tire in the new state is known.
(1) Tire constant rewriting method (method A)

Input the primary password and secondary password.
Select the tire constant from the tire constant table below.
3-38
On the display, the speedometer indicates the current tire constant (2 numeral digits)
and the hour meter indicates the tire mark indicator.
Each time the power control select switch is pressed, the 10’s digit or 1’s digit of the
tire constant blinks alternately. The blinking numeral is incremented or decremented
when the level setting (up or down) switch is pressed. Set the tire constant selected in
step . (The tire constant can be set between 00 and 99.)
To increase the tire constant: Press the up switch. (Increments by 1 each time.)
To decrease the tire constant: Press the down switch. (Decrements by 1 each time.)
Select any of the three following methods for returning from the tire constant rewriting
mode:
• Press the hour meter select switch to return to the standard (speed) display.
• Turn the key switch to the OFF position.
• Leave the state unchanged. (Automatic returning to the standard display occurs in 2 minutes
if no operation is made.)
1. Tire constant rewriting method (method B)

Obtain the tire constant as follows:
[Cushion tire]
Set the no load state, measure dimension A
in the figure, and calculate tire constant W by
the following equation:
• W = 0.55A (mm) - 100
(W = 14A (in) - 100)
[Pneumatic tire and unique track-shoe tire]
With a load at 1/2 of the maximum allowable
load on the fork, measure dimensions A and
B in the figure.
Calculate the tire constant W by the follow-
ing equation:
• W = 0.31A (mm) + 0.23B (mm) - 85
(W = 7.9A (in) + 5.8B (in) - 85)
Count fractions of 5 and over as 1 and disre-
gard the rest.
Input the primary password and secondary
password. (See method A.)
Then, follow steps 3 and 4 in method A.
Use the value calculated from the actually
measured value as the tire constant.
3-39
(3) Tire constant rewriting method (method C)

Obtain the tire constant as shown below.
Calculate tire wear C by the following equa-
tion:
C = Tire radius in new state - radius of
worn tire
Calculate tire constant W by the following
equation:
W = W’ - 1 C (mm)
2
(W = W’ - 12.7 C (in))
W’ = Tire constant in new state
Input the primary password and secondary
password. (See method A.)
Rewrite the tire constant according to steps
and 4 in method A by using the tire con-
stant calculated from the tire wear.
Battery electrolyte level warning

The warning function can be enabled or disabled by
password input. If A1 is indicated on the speed display
portion, the warning function is enabled. If A0 is indi-
cated, this function is disabled.
Power control input

The power control input can be locked or unlocked by
password input. If P is indicated on the speed display
portion upon password input, the power control input’
is set to the locked state. If PO is displayed, the power
control input is unlocked.
Battery (mounted/not mounted)

It is possible to select battery mounted state or not
mounted state by passwork input. The speedometer
on the display indicates T1 when the not mounted
state is selected, and T0 when the mounted state is
set.
Note: This data is provided for changing over the constant

for calculation for the battery charge indicator. Set it to the
mounted state when the standard battery is to be used, or
to the not mounted state when any other type of battery is
to be used.
3-40
7. Option input mode
These are passwords for option items newly added in the 5FBE series.
As these are set according to the specifications at the time of new vehicle delivery, no setting is re-
quired unless any change is made.
The items with * are not provided in the vehicle specifications. Although indication on the display ap-
pears, proceed to the next option item by pressing the power control select switch.
These items should be set in any of the following cases:
• When the display board is replaced
• When a demonstration is to be made
• When the parking brake application failure warning is to be reset
3-41
(1) Demonstration mode switching effective/ineffective.

For the transportation reason, the condition of the truck before starting the hourmeter has
been so arranged that the parking application failure warning and the simultaneous opera-
tions of the traveling and material handling should be preset to “Ineffective”.
This condition, however, is changeable to “Effective” by turning the demonstration mode on
the mask function.
This changeover, in especial, in useful for the demonstration of the New Trucks, where the
warning and simultaneous operation are in need.
Use the UP or DOWN switch for selection.

Press the UP switch to change from ineffective to effective. Press the DOWN switch to change form
effective to ineffective. Pressing the UP switch in the effective state or the DOWN switch in the inef-
fective state causes no change. When the power control select switch is pressed, the next option item
is selected.
When the hour meter changeover switch is pressed, the mode returns from option input to normal dis-
play.
Note:
It takes about a second after pressing the select (UP or DOWN) switch until display change.
3-42
(2) Parking brake application failure warning effective/ineffective selection
Parking brake application failure alarm : Parking brake application failure alarm :
Effective Ineffective
(Note) Keep the setting at Effective as the ineffective specification is not provided as the vehicle specification.
(3) Voltage selection
36 V specification 48 V specification
(Note) As 36V specification is not provided as the vehicle specification.

Keep this setting at 48V.
3-43
(4) Material handling chopper provided/not provided selection

The method is the same as that for demonstration mode selection in item (1) above.
With material handling chopper Without material handling chopper
(5) Speed control switch set/reset selection

The method is the same as that for demonstration mode selection in item (1). The operation,
however, shall be made after pressing the speed control switch to on.
Switch : Set
Switch : Reset
(Note) Keep this setting at Set as speed control switch reset is not provided as the vehicle specification.
4-3
GENERAL
This troubleshooting is to pursue the causes of diagnostic errors indicated by the error codes on the
multi-display and other electric troubles for quick repair.
Measuring instruments such as the megger and multimeter (circuit tester) are used for the error check.
Some error items may be checked by the analyzer on the vehicle.
Descriptions in this manual are for the mechanics who have mastered handling of measuring instruments,
can read wiring and connection diagrams accurately and can make actual measurements using the con-
nector drawing.
Please make use of the attached connection diagram, connector drawing and connector terminal ar-
rangement.
TROUBLESHOOTING EXPLANATION
1. Drive system material handling system troubles
(1) When an error code is displayed:

See the “Diagnosis Errors” section.
(2) When no error code is displayed:
1. Drive system abnormality
See the “When Diagnostic Result is Not Displayed (Drive System)” section.
2. Material handling system abnormality
See the “When Diagnostic Result is Not Displayed (Material Handling System)” section.
2. Trouble shooting-other
See the “Trouble shooting-other” section
3. Troubleshooting related to multi-display and MCS communication system

See the “Multi-display MCS Communication System” section.
4. Steering system troubleshooting

(1) When an error code is displayed:
See the “Diagnosis Error” section.
(2) When no error code is displayed (STD):
See the “No Diagnosis Error” section.
(3) When no error code is displayed (w/EHPS)
See the “No Diagnosis Error” section.
4-3
TROUBLESHOOTING EXPLANATION
I
Indicates the item that can be checked by the analyzer.

(Single frame is used when analyzer check is impossible.)
4-4
DRIVE SYSTEM MATERIAL HANDLING SYSTEM TROUBLES
WHEN DIAGNOSTIC ERROR CODE IS DISPLAYED
ERROR CODE A0: MCS MAIN CIRCUIT OVERHEAT

4-5
Inspection 1. Temperature sensor resistance check

Battery plug OFF, connector STH disconnection
OK (less than 2 k) CPU board defect, or defective contact or disconnection between CN104
and connector STH
NG (2 k or more) Temperature sensor defect
4-6
ERROR CODE A2: CPU BOARD ABNORMAL TEMPERATURE RISE
f* The CPU temperature sensor is included on the CPU board. CPU board defect is conceivable
when this error code (A2) is displayed.
4-7
ERROR CODE A3: ABNORMALLY HIGH BATTERY VOLTAGE

4-8
Inspection 1. Battery voltage measurement

Battery plug OFF
* The criterion in troubleshooting is 69 V or less.

ERROR CODE A4: ACCELERATION POTENTIOMETER INSTALLATION DEFECT
4-10
Inspection 1. Individual acceleration potentiometer inspection

Individual acceleration potentiometer removal
OK ( Ω in ordinary state and 0 in operated state) → Installation adjustment defect

8
NG (Always 0 Ω )→ Acceleration potentiometer defect

4-11
ERROR CODE A6: MATERIAL HANDLING SWITCH INSTALLATION ABNORMALITY

4-12
A
(When LS2 is ON)
(When LSL is ON)
For LST, LSAT1, LSAT2 and LSAT3, carry out troubleshooting in the same way as for LSL.
4-13
Inspection 1. LSL2 individual check

LSL2 individual removal
OK ( Ω at switch OFF) → Installation readjustment

8
NG (0 Ω at switch OFF) → LSL2 replacement
Inspection 2. LSL individual check

LSL individual removal

8
NG (0 Ω at switch OFF) → LSL replacement

4-14
ERROR CODE A7: PARKING BRAKE ALARM
4-16
Inspection 1. Parking brake switch individual check

Parking brake switch individual removal

8
NG (0 Ω at switch OFF) → Switch replacement
Inspection 2. Deadman switch individual check

Deadman switch removal
OK (0 Ω at switch ON) → Installation adjustment defect

NG ( at switch ON) → Switch replacement
8
4-17
ERROR CODE A8: TRAVELING FUSE ABNORMALITY

4-18
Inspection 1. Travelling fuse (F1) check
Battery plug OFF
OK (0) → To inspection 2
NG ( ) → F1 replacement To inspection 3
OK (battery voltage)
NG (0 V) → Disconnection in battery cable between battery and fuse F1
4-20
Inspection 3. P2-N1 resistance measurement

Battery plug OFF
OK (other than 0) → Normal

NG (0) → Contact between P2 wiring and N1
Inspection 4. P9 voltage input check

SWKY OFF and use of SST
* The criterion in troubleshooting is 5 V or more.

4-21
ERROR CODE AA: CPU BOARD TEMPERATURE SENSOR OUTPUT ABNORMALITY
ERROR CODE AE: EXCESSIVE A/D PROCESSING TIME
CPU board replacement for AE display
ERROR CODE AF: CPU PROCESSING DATA ABNORMALITY
CPU board replacement for AF display

4-22
ERROR CODE C0: MAIN DRIVE CIRCUIT ABNORMALITY

4-23
4-24
4-25
Inspection 1. P7-N1 Voltage check
Battery plug ON, SWKY OFF, direction switch OFF, acceleration switch OFF
OK (8 V or more) To inspection 2 The standard voltage between P7 and N1 is as

NG (less than 8 V) To inspection 4 shown above, but the criterion for troubleshoot-
ing is 8 V or more.
Inspection 2. TM-DC/SDD continuity check

Battery plug OFF, SST connection
OK (0 ) To inspection 3
NG Wiring disconnection
4-26
nspection 3. CPU-DC/SDD continuity check

OK (0 Ω ) → DC/SDD board defect or CPU board defect

NG (∞ Ω ) → Wiring disconnection
Inspection 4. TM individual check

Battery plug OFF, copper bar disconnection
4-27
4-28
Inspection 5. P2-DAD cathode (heat sink) continuity check

Battery plug OFF
OK (approx. 1.5 ) To inspection 6.

NG ( ) To inspection 7.
Inspection 6. (CN102-5 - DAD cathode CN102-4 - TM (D)) Continuity check

OK → DRIVE DC/SDD board defect

NG → Wiring disconnection
4-29
Inspection 7. Individual RAD measurement

Battery plug OFF, CN118 disconnection
Ω →
∞Ω
OK (approx. 1.5 ) Disconnection between main circuit and CN117 CN118
NG ( ) RAD defect
Inspection 8. Individual DF1 check

Battery plug OFF, DF1 wiring disconnection
Ω ∞Ω →
→
OK (forward: approx. 3 k , reverse: ) To inspection 9
NG Discoloration or loosening of DF1 set screw or copper bar
4-30
Inspection 9. Individual DAD measurement

Battery plug OFF, DAD wiring disconnection
OK (forward: approx. 6 k Ω , reverse:∞ Ω ) → Loosening of CAD wiring or copper bar

NG → Loosening of DAD lead or round terminal
4-31
ERROR CODE C1: DRIVE CIRCUIT CURRENT SENSOR ABNORMALITY
4-32
Inspection 1. CSD output voltage measurement

Battery plug ON, SWKY ON, SST connection
OK (approx. 1.2 V) → CPU board defect or drive motor defect (short circuit)
NG (over 2.0 V or less than 0.35 V) → CSD defect, or wiring defect
4-33
ERROR CODE C4: TRAVELING ACCELERATOR ABNORMALITY
*The acceleration potentiome-

ter is defective if the switch
is not turned ON.
4-34
B
Recheck after disconnecting the acceleration
potentiometer connector.
4-35
Inspection 1. Individual acceleration potentiometer measurement

Battery plug OFF
YES (variation from O Ω to about 2 ~ 4 k Ω) → Acceleration potentiometer adjustment defect

NO → Acceleration potentiometer replacement
Inspection 2. Individual acceleration potentiometer check

Same as inspection 1.
4-36
ERROR CODE C7: DIRECTION SWITCH ABNORMALITY

4-37
ERROR CODE C8: SPEED SENSOR ABNORMALITY

4-38
A
4-39
Inspection 1. Individual speed sensor measurement

Battery plug OFF
OK (approx. 700 Ω ) → CPU board defect

NG (other than 700 Ω ) → Speed sensor replacement
4-40
ERROR CODE C9: MF. MR CONTACTOR DRIVER ABNORMALITY

4-41
4-41
4-42
The standards for inspection 1 to inspection 4 are the same as the inspection standard for each element.
Inspection 5. SN1 inspection

Disconnect SN 1 wiring
OK → CPU board defect, harness pinching, or DC/SDD defect

NG → Replace the part judged NG.
4-43
ERROR CODE CA: MF MR CONTACTOR DRIVE CIRCUIT ABNORMALITY
Replace the CPU board when CA is displayed.

ERROR CODE CE: ROM ABNORMALITY IN CPU
Replace the CPU board when CE is displayed.

ERROR CODE CF: RAM ABNORMALITY IN CPU
Replace the CPU board when CF is displayed.

4-44
ERROR CODE EO: MAIN MATERIAL HANDLING CIRCUIT ABNORMALITY
Pump fuse (F2) flown
TMP defect
Main material handling circuit connection defect
Open circuit, connector disconnection or defective contact in RAP wiring
Disconnection or defective contact of wiring between TMP and DC/SDD
Disconnection of wiring between CPU and DC/SDD
Defective contact of each connector
Material handling DC/SDD board defect
CPU board defect

4-45
4-46
B
4-47
Inspection 1. Pump fuse (F2 check)

Battery plug OFF
OK (O Ω) → Check disconnection of each connector and loosening of TMP connection.

NG (∞ Ω ) → F2 replacement
Inspection 2. P13-N1 voltage measurement

Battery plug ON, SWk ON
OK (8 V or more) → To inspection 3 The standard voltage between P13 and N1 is as

NG (less than 8 V) → To inspection 5 shown above, but the criterion for troubleshoot-
ing is 8 V or more.
4-48
Inspection 3. TMP-DC/SDP continuity check

OK (O Ω ) → To inspection 4
NG ( ∞ Ω ) → Wiring disconnection
Inspection 4. CPU-DC/SDP continuity check

OK (O Ω) → DC/SD board defect or CPU board defect

NG (∞ Ω )→ Wiring disconnection
4-49
Inspection 5. Individual TMP check

Battery plug OFF, TMP wiring and copper bar disconnection
OK To inspection 6
NG To inspection 8
4-50
Inspection 6. P11-DAP cathode (heat sink) continuity check

Battery plug OFF
OK (approx. 1.5 ) To inspection 7

NG (∞ Ω ) To inspection 10
Inspection 7. CN112-5 - DAP Cathode and CN112-4 TMP (D) continuity check
Battery plug OFF
OK (0 Ω ) → Material handling DC/SDP defect or CPU board

defect
NG (∞ Ω) → Wiring disconnection
4-51
Inspection 8. Individual DF3 measurement

Battery plug OFF, DF1 wiring connection
OK (forward: approx. 3 kΩ, reverse: ∞ Ω ) → To inspection 9

NG → DF3 defection, or discoloration or loosening of screw and copper bar
4-52
Inspection 9. Individual DAP measurement

Battery plug OFF, DAP wiring disconnection
OK (forward: approx. 6 kΩ , reverse: ∞ Ω) → Loosening of DAP wiring or TMP copper bar terminal
NG → Loosening of DAP lead or round terminal
Inspection 10. Individual RAP measurement

Battery plug OFF, CN119 disconnection
OK (approx. 1.5 Ω ) → Main circuit ~ CN 117 ~ CN119 open circuit

NG (∞ Ω) → RAP defect
4-53
ERROR CODE E1: MAIN MATERIAL HANDLING CIRCUIT CURRENT SENSOR

ABNORMALITY
4-54
Inspection 1. CSP output voltage measurement

Battery plug ON, SWKY ON, and use of SST
OK (approx. 1.2 V) → CPU board defect

NG (2.5 V or more) → CSP defect or wiring defect
4-55
ERROR CODE E3: RETURN TO NEUTRAL
Estimated causes
Momentary disconnection of battery plug power supply line
Direction switch defect
Direction switch wiring short-circuit
Accelerator switch defect
Accelerator switch short-circuit
Deadman switch defect
Deadman switch wiring defect
CPU board defect
DC/SDD defect
4-56
4-57
Inspection 1. Deadman switch individual check

Deadman switch removal
OK → Momentary disconnection of the line between CN106 and CN22, momentary disconnec-
tion of the B/T plug power supply line, DC/SDD defect, or CPU board defect
NG → Deadman switch defect
Inspection 2. Direction switch individual check

Direction switch removal
OK → CN106-CN9 wiring short-circuit or CPU board defect

NG → Direction switch defect
4-58
Inspection 3. Accelerator switch individual check

Accelerator switch removal
OK → Momentary interruption between CN106 and CN25, or CPU board defect

NG → Accelerator switch defect
4-59
ERROR CODE E6: MATERIAL HANDLING SWITCH ABNORMALITY

4-60
ERROR CODE EE: MCS RECEIVING DATA ABNORMALITY
ERROR CODE EF: CPU PROCESSING TIME ABNORMALITY

4-61
ERROR CODE F9: STEERING POTENTIOMETER DEFECT

4-62
Inspection 1. Steering potentiometer output voltage check

Battery plug ON, voltage check below while rotating the wheel slowly
OK → ANL12: Test operation

NG → To inspection 2
Inspection 2. Steering potentiometer indurdual check

Steering potentiometer wiring disconnection
OK → Wiring disconnection or short circuit

NG → Steering potentiometer
4-63
ERROR CODE FA: RAD DISCONNECTION

4-64
A
4-65
Inspection 1. RAD individual check

RAD removal
OK → Approx. 1.5
NG → RAD defect
Inspection 2. P9 voltage input check

SWKY OFF, use of SST
OK → To inspection 3
NG → P2 ~ CN117 ~ CN118 ~ P9 ~ CN104 wiring defect
4-66
Inspection 3 Battery voltage input check

SWKY OFF, of SST
OK → CPU board defect

NG → DC/SD board or wiring defects
4-67
WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED (DRIVE SYSTEM)

1. The vehicle does not move at all. (The multi-display is kept off even when the key
switch is turned ON.)
4-68

Battery plug ON
OK (battery voltage) → To inspection 2

NG (O V) → Battery connector defect, blown F5 fuse, or battery internal wiring disconnection
Inspection 2. Voltage measurement after SWKY
Battery plug ON, SWKY ON

NG (O V) → SWk defect, or wiring defect
4-69
Inspection 3. DC/SDD supply voltage measurement

Battery plug ON, SWKY ON
OK (approx. 25 V) → CPU board defect

NG (0 V) → To inspection 4
Inspection 4. DC/SDD Supply voltage measurement

Battery plug ON, SWKY ON, CN107 connector disconnection
OK (approx. 25 V) → Display defect, or CN107 display

wiring defect (short circuit}
NG (0 V) → To inspection 5
4-70
Inspection 5. DC/SDD supply voltage measurement

Battery plug ON, SWKY ON, CN104 CPU board side connector disconnection
OK (approx. 25 V) → CPU board defect

NG (0 V) → DC/SD defect, or CN101 CN104 wiring defect
(short circuit)
4-71
2. The vehicle does not move at all. (The MF(MR) contactor is not closed when the
direction lever is set to the forward (or reverse ) position or when the accelerator
is depressed.)
4-72
4-73

Battery plug ON
OK (15 V battery voltage or more)

→ ANL31: Switch input test
NG (0 V) → Battery overdischarge
Inspection 2. MFR•MFL •MRR •MRL contactor coil continuity check

Battery plug OFF, MFR •MFL •MRR •MRL connector disconnection
OK (approx. 20 Ω) → CPU board defect, wiring disconnection (between CPU board and
MFR •MFL •MRR •MRL contactor)
NG (∞ Ω) → MFR MFL MRR MRL contactor replacement
4-74
The vehicle does not move at all. (The MF R •MF L •MR R and MR L contactors are
closed.)
* Approx. 0 Ω is the motor

coil resistance very close to
0.
4-75
Inspection 1. Drive motor continuity check

Battery plug OFF, cable disconnection from P4 to P7 P41 to P61
OK (approx. 0) CPU board defect

NG () Armature coil disconnection or field coil disconnection
4-76
5. Normal speed control fails. (Acceleration failure)

4-77
A
4-78
Inspection 1. Drive circuit OCL value measurement

See the OCL value measurement (page 2-35) in the controller section.
Inspection 2. Individual brake switch check

Battery plug OFF Brake switch removal
OK (switch OFF:) → To inspection 3

NG (switch OFF: 0) → Brake switch replacement
Inspection 3. Brake switch installation adjustment check

See the brake switch adjustment (page 2-38) in the controller section.
4-79
6. The maximum traveling speed is not attained.

4-80
A
4-81
7. Excessive braking in switch back operation.

4-82
Inspection 1. DF2L DF2R individual check

Battery plug OFF, DF2L DF2R wiring disconnection
OK → CPU board defect

NG → DF2L DF2R defect
4-83
8. The vehicle travels only in the forward or reverse direction.

4-84
Inspection 1. MFR MFL or MRR MRL contactor coil continuity check

Battery plug OFF
OK (approx. 20) → CPU board defect, or wiring disconnection (between CPU board and
contactor coil)
NG ( Ω) → MFR ·MFLor MRR ·MRL contactor replacement
8
4-85
9. The speed limiter is ineffective.
(1) The vehicle speed rises to the maximum speed.

4-86
(2) The limited speed is abnormal.

4-87
WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED
(MATERIAL HANDLING SYSTEM)
1. The pump motor does not run.
(1) When material handling chopper is provided. (Option)

4-88
A
4-89
Inspection 1. F2 fuse continuity check

Battery plug OFF
OK (0 Ω) → MP closing check at SWKY ON

NG ( Ω) → F2 fuse replacement
8
Inspection 2. MP contactor coil continuity check

Battery plug OFF
OK (approx. 20Ω) → CPU board defect, or wiring disconnection (between CPU board and contactor)
NG ( Ω) → MP contactor coil replacement
8
4-90
Inspection 3. Pump motor continuity check

Battery plug OFF, P12· P13 motor cable disconnection
OK (approx. 0 Ω) → CPU board defect or DC/SDP board defect

NG ( Ω) → Motor coil disconnection
8
4-91
(2) When the material handling chopper is not provided. (Standard)

4-92
Caution:
Never touch the material handling lever during MP contactor operation check.
Otherwise, the pump motor starts to move the mast and fork when the MP contactor is closed.
4-93
Inspection 1. F2 fuse continuity check

Battery plug OFF
OK (0 Ω) → Check MP closing at SWKY ON

NG ( Ω ) → F2 fuse replacement
8
Inspection 2. MP contactor coil continuity check

Battery plug OFF
OK (approx. 20 Ω) → CPU board defect, or wiring disconnection between CPU board and contac-
tor coil
NG ( Ω) → MP contactor replacement
8
4-94
TROUBLESHOOTING - OTHERS
Battery capacity is not indicated correctly.

4-95
TROUBLESHOOTING RELATED TO MULTI-DISPLAY AND MCS

COMMUNICATION SYSTEM
ERROR CODE F1: FAILURE IN COMMUNICATION BETWEEN MULTI-DISPLAY AND MCS
ERROR CODE F2: FAILURE IN COMMUNICATION BETWEEN MULTI-DISPLAY AND MCS
ERROR CODE F3: POWER CONTROLLER MEMORY VALUE INCONSISTENCY
ERROR CODE F4: POWER CONTROLLER MEMORY VALUE ABNORMALITY
Multi-display board defect
ERROR CODE F5: CHARGING TIMER MEMORY ABNORMALITY
Note
Even if error code F5 is displayed when the AC power is connected, charging is possible by pressing
the CHARGE switch. As the count memory for automatic equalized charging is abnormal, automatic equal-
ized charging fails.
4-96
ERROR CODE F6: CHARGING SAFETY TIMER OPERATION

4-97
ERROR CODE F7: CHARGING START FAILURE
ERROR CODE F8: CHARGING NOT COMPLETED

4-98
STEERING SYSTEM TROUBLES

DIAGNOSIS ERRORS
ERROR CODE F0: STD (WITH CONTACTOR)
F0 is not displayed for a trouble on the PS side because the standard PS system is not prourded with
the diagnostic junction.
ERROR CODE: F0 (WITH EHPS)

4-99
A
4-100
Inspection 1. Display signal voltage check

Battery plug ON, SWKYON, CN27 connection
OK (0 V on both harness side and board side) → Display board defect

NG (5 V on harness side and 0 V on board side)→ CN27 defect
NG (5 V on both harness side and board side) → PS board defect
Inspection 2. PB board signal voltage check

Battery plug ON, SWKYON, CN27, CN41 and CN43 in connected state
OK (battery voltage on both harness side and board side) CN41 CN43 defect, PS controller in-
ternal wiring defect, or PS board
defect
NG (battery voltage on harness side and 0 V on board side) CN27 defect
NG (0 V on both harness side and board side) wiring disconnection
4-101
WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED (STD)

1. The steering wheel is heavy. (The PS motor does not run when the direction switch
is closed and the parking brake is released after SWKY is turned to ON.)
4-102
Inspection 1. Main PS circuit voltage measurement

Battery plug ON, SW KYON, CN27 connection
OK (Battery voltage) → Motor cable or connector defect, or motor defect

NG (0 V) → F3 fuse defect, wiring disconnection, or contactor contact defect
Inspection 2. Mps contactor coil continuity check

Battery plug OFF
OK (approx. 110 Ω) → CN42 defect, wiring disconnection, direction switch defect, CPU board
defect, or parking switch defect.
NG ( Ω ) → Mps contactor defect
8
4-103
WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED (W/EHPS)
1. The steering wheel is heavy. (The PS motor does not run when the steering wheel
is operated after the SWKY is turned to ON.)
4-104
4-105
Inspection 1. Main PS circuit voltage measurement (1)

Battery plug ON, SW KYON, CN41 CN43 connection

NG (0 V) → F3 fuse defect, CN41 defect, PS controller internal wiring defect
Inspection 2. Main PS circuit voltage measurement (2)

Battery plug ON, SWKYON, CN41 CN43 connection, steering wheel in non-operated
position
Battery voltage → To inspection 3

Less than battery voltage → CN41 43 defect, CPU board defect, motor or cable connector defect
4-106
Inspection 3: Main PS circuit voltage measurement (3)

Battery plug ON, SW KYON, CN41 43 connection, steering wheel in operated state

NG (about half of battery voltage) → Motor defect or PS pump defect
Inspection 4. Steering pressure switch operating voltage measurement (1)

Battery plug ON, SWKY ON, CN27 connection
OK (approx. 12 V) → To inspection 5
NG (0 V) → CN27 defect or PS board defect
4-107

Battery plug ON, SW KYON, CN27 connection, with steering wheel rotation
OK (2 V or less when the steering wheel is not operated, and 10 V or more when the steering wheel
is operated) → PS circuit TMps defect, PS circuit current sensor defect, or PS board defect
NG → Steering pressure switch
4-108
2. The PS motor keeps running after SWKYON. (STD with contactor)

4-109

Battery plug ON, SWKY ON, CN27 connection
OK (2 V or less when the steering wheel is not operated, and 10 V or more when the steering wheel
is operated) → PS board defect
NG → Steering pressure switch defect, or wiring defect
5-2
DRIVE MOTOR
GENERAL
SPECIFICATIONS
5-3
COMPONENTS
1401
1401-067F
5-4
.
Removal Procedure
1 Remove the battery ASSY.

(See page 1-5 “Battery Assy Removal Installation”.)
2 Remove the rear toe board and front toe board.
3 Remove the steering wheel.

(See 8-11 in the “Steering Wheel Removal - Installation” section on page 1-3.)
4 Drain the brake fluid.
5 Remove the disc brake LH.
6 Disconnect the drive motor LH wiring.
7 Remove the drive motor LH. [Point 1]
8 Remove the disc brake RH.
9 Disconnect the inlet hose and high pressure hose from the control valve.
10 Disconnect the drive motor RH wiring.
11 Remove the drive motor RH. [Point 2]

5-5
Point Operation
[Point 1]
Removal Installation: SST 09010-10260-71
[Point 2]
Removal Installation: SST 09010-10200-71

5-6
Note:
Measure the insulation resistance of each motor cable and motor unit before starting disassembly.
Ω or more
Standard: 3 MΩ
1 Remove the disc brake.
2 Remove the brush cover.
3 Free the brush.
4 Remove the bracket, No. 1.
5 Remove the armature coil. [Point 1]
6 Remove the commutator frame. [Point 2]
7 Remove two brushes from the commutator frame. [Point 3]
8 Remove the brush holders from the commutator frame.
9 Remove the field coil. [Point 4]
Note:
• Measure the insulation resistance between each motor cable and motor case.
Standard: 3 M or more
• Field coil continuity inspection. Terminals to be measured: E and F
Standard: 0 (circuit tester range:)
5-7
Point Operations
[Point 1]
Removal: SST 09950-20017
Inspection: If the commutator surface is roughened, cor-

rect it with sandpaper (around # 600) and
clean it carefully. If heavily roughened, correct
it with a lathe.
Commutator outside diameter
Inspection: Carry out undercutting of mica when the com-

mutator is corrected.
Undercut depth
Standard: 1.0 mm (0.039 in)

Limit: 0.3 mm (0.012 in)
Inspection: Measure the insulation resistance of the arma-

ture coil.
[Point 2]
Inspection: Install the armature and brushes. Attach a

spring scale to the brush spring and measure
the spring force on the instant when the spring
departs from the brush.
Spring force
5-8
Inspection: Measure the insulation resistance between the

brush holder and bracket.
Ω or more
Standard: 1 MΩ
[Point 3]
Inspection: Inspect the brush wear and contact states.
Standard: 32 mm (1.26 in)

Limit: 14 mm (0.55 in)
[Point 4]
Inspection: Inspect the continuity of the field coil.
Measurement terminals: E-F
Standard: 0 (circuit tester range:Ω Ω)
Inspection: Measure the insulation resistance of the field

coil
Measurement position: Between E-F terminal

and yoke
Standard: Ω or more
1 MΩ
5-9
PUMP MOTOR
GENERAL
SPECIFICATIONS
5-10
COMPONENTS
1402
1402-091
5-11
Removal Procedure
1 Remove the battery hood.
2 Remove the rear panel.
3 Remove the panel.
4 Disconnect the inlet hose and high pressure hose.
5 Disconnect the motor wiring.
6 Slightly hoist the motor. [Point 1]
7 Remove the motor W/oil pump.
8 Disassemble the motor and oil pump.
5-12
Point Operations
[Point 1]
Removal: SST 09010-10260-71

5-13
Note:
2 Brushes
1 Raise the brush cover.
2 Free the brushes.
3 Remove the bracket No. 1.
5 Remove the commutator frame. [Point 2]
6 Remove two brushes from the commutator frame. [Point 3]
7 Remove the brush holders from the commutator frame.
8 Remove the yoke ASSY. [Point 4]
Note:
• Measure the insulation resistance between each motor cable and motor case.
Standard: 1 MΩΩ or more
• Field coil continuity inspection. Terminals to be measured: E and F
Standard: 0 Ω
5-14
Point Operation
[Point 1]
Disassembly: SST 09950-20017

rect it with sandpaper (around # 600) and clean
it carefully. If heavily roughened, correct it with
a lathe.
Commutator outside diameter
Inspection: Carry out undercutting of mica when the com-

mutator is corrected.
Limit: 0.3 mm (0.012 in)

ture coil.
Standard: 1 M Ωor more
[Point 2]

spring scale to the brush spring and measure
the force on the instant when the spring de-
parts from the brush.
Spring force
5-15
Inspection: Measure the insulation resistance between the

brush holder and bracket.
1 MΩ
[Point 3]

[Point 4]
Installation: Field coil continuity inspection.
Measurement terminals: Between E and F

Standard: 0ΩΩ (circrit tester range: Ω)
Installation: Measure the insulation resistance of the field

coil.
Measurement position: Between E-F terminal
and yoke
5-16
POWER STEERING MOTOR

GENERAL
SPECIFICATIONS
5-17
COMPONENTS
1403
1403-029
5-18
REMOVAL ·INSTALLATION
2 Rear toe board·Front toe board
Removal Procedure
1 Remove the side cover RH.
3 Disconnect the power steering motor wiring.
4 Disconnect the power steerig pump piping.
5 Remove the power steering motor ASSY w/power steering pump.
6 Disconnect the power steering pump.
7 Remove the bracket.
8 Remove the power steering pump mounting.
9 Disconnect the power steering motor ASSY.

5-19
DISASSEMBLY · INSPECTION · REASSEMBLY

Note:
Ω or more
Standard: 1 MΩ
3 Raise the Brush
1 Remove the PS contactor.
2 Remove the brush cover.
3 Raise the brush.
4 Remove the bracket.
6 Remove the commutator frame ASSY. [Point 2l
7 Remove the brush holders ASSY. [Point 3]
Note:
l Measure the insulation resistance between each motor cable and motor case.
Ω or more
Standard: 1 MΩ
5-20
Point Operations
[Point 1]

rect with sandpaper (around # 600) and clean it
carefully.
If heavily roughened, correct it with a lathe.
Commutator outside diameter.

Inspection: When the commutator is corrected, undercut

the mica.

Limit: 0.3 mm (0.012 in)

ture coil.
1 MΩ
[Point 2]

spring scale to the brush holder, and measure
the force when the spring departs from the
brush.
Standard: 5.59 N (0.57 kg) [1.26 lb]

Limit: 2.75 N (0.28 kg) [0.617 lb]
[Point 3]

5-21
Inspection: Insulation resistance between the holder and

bracket.
6-2
GENERAL
6-3
SPECIFICATIONS
COMPONENTS
4201
4201-115
6-4
TRANSMISSION
1 Transmission oil
Removal Procedure
1 Drain transmission oil.
2 Remove mast ASSY. (See Mast ASSY Removal on page 12-5.)
3 Remove drive motors LH and RH. (See Drive Motor Removal on page 5-4.)
4 Jack up the frame and remove front wheels.
5 Remove transmission case LH. [Point 1]
6 Remove transmission case RH. [Point 2]
Note:
l Fill transmission oil to the level plug position
Right side: 1.7 l (0.45 Usgal)
Left side: 1.8 l (0.47 USgal)
Standard vehicle: Hypoid gear oil SAE 85W-90
Insulated vehicle: Hypoid gear oil SAE 75W-80W
l Front whell hub nut tightening torque: 107.87-147.10 N·m (1100-1500 kg-cm)
[79.59-108.53 ft-lb]
6-5
Point Operations
[Point 1]
Removal·lnstallation: Install shackles at drive motor instal-

lation holes and hoist with a wire
rope.
[Point 2]
Removal lnstallation: Install shackles at drive motor instal-

lation hole and hoist with a wire
rope.
6-6
DISASSEMBLY·INSPECTION·REASSEMBLY
1 Remove the front axle hub. [Point 1]
2 Remove the transmission cover.
3 Remove the gears (63T and 16T). [Point 2]
4 Remove the front axle shaft. [Point 3]
5 Remove the gears (74T and 25T). [Point 4]
6 Remove the gear (22T). [Point 5]

7 Remove the oil seal.
Note:
l Coat liquid gasket (Three Bond 1215 or equivalent) on the transmission cover mating face before
reassembly.
l Fill MP grease 0.490N (50 9) [0.110 lb] in the hub cap. Use MIL-G-3278-A only in the case of insu-
lated model 45S.
l Transmission cover set bolt tightening torque: 29.42-44.13 N m (300-450 kg-cm) [21.71-32.56 ft-
lb]
l Check the clearance between the tip end of the speed sensor and the gear. If it is not within the
standard, adjust it by changing the washer.
Standard: 0.5-2.5 mm (0.020-0.098 in)
6-7
Point Operations
[Point 1]
Inspection: Inspect the front axle hub preload.
Standard: 59-88 N (6-9 kg) [13-20 lb]
[Point 2]
[Point 3]
[Point 4]

6-8
[Point 5]

6-9
FRONT AXLE
1 Jack up the vehicle and remove the front wheels.
2 Remove the front axle hub. [Point 1]
Note:
l Fill MP grease 0.490N (50 9) [0.110 lb] in the hub cap. Use MIL-G-3278-A only in the case of insu-
lated model 45S.
l Front wheel hub nut tightening torque: 107.87-147.10 N·m (1100-1500 kg-cm) [79.59-108.53 ft-
lb]
6-10
Point Operations
[Point 1]
Inspection: Inspect the front axle hub preload.
Standard: 59-88 N (6-9 kg) [13-20 lb]

7-2
REAR AXLE ASSY

GENERAL
1.0 and 1.3 ton series, and cushion vehicles of 1.0, 1.3, 1.5 and 1.8 ton series
7-3
1.5 and 1.8 ton series

7-4
SPECIFICATIONS
COMPONENTS
4301
4301-086
7-5
REMOVAL·INSTALLATION
Removal Procedure
2 Remove the weight.
3 Jack up the vehicle and remove the rear wheel.
4 Remove the cylinder. (See Steering Cylinder ASSY Removal on page 8-15.)
5 Remove the rear axle ASSY. [Point 1]
Note:
Rear wheel hub nut tightening torque: 107.87-147.10 N m (1100 1500 kg-cm)
[79.59 108.53 ft-lb]
7-6
Point Operations
[Point 1]
Inspection: Inspect the rear axle ASSY preload.
Standard
1 ton series: 69 ~ 137 N (7 14 kg) [15 31 lb]
1.5 ton series: 78 ~ 147 N (8 15 kg) [18 33 lb]
Measure at the center of the rear axle in the 1 ton se-
ries, and at the hub bolt in the 1.5 ton series.
7-7
Remove the hub cap.
Remove the rear axle hub. [Point 1]
Remove the axle shaft bearing. [Point 2]
Remove the bearing on the axle shaft wheel side. [Point 3]

Note:
l Fill MP grease in the hub cap. Use MIL-G-3278-A only in the case of the insulated model 45S.
Axle shaft side: 0.785 N (80 g) [0.176 lb]
Axle shaft wheel side cap: 0.2452 N (25 g) [0.0551 lb]
l Rear wheel hub nut tightening torque: 107.87 147.10 N m (1100 1500 kg-cm)
[79.59 108.53 ft-lb]
7-8
Point Operations
[Point 1]
Inspection: Inspect the rear axle hub preload.
Standard: 49 ~ 78 N (5 8 kg) [11 18 lb]
[Point 2]
[Point 2]

7-9
REAR AXLE HUB

Removal Procedure
1 Jack up the vehicle and remove the rear wheel.
2 Remove the hub cap.
3 Remove the rear axle hub. [Point 1]
4 Remove the bearing on the axle shaft wheel side. [Point 2]
Note:
Fill MP grease in the hub cap. USE MIL-G-3278-A only in the case of the insulated model 45S.
• Axle shaft side: 0.785 N (80 g) [0.176 lb]
Axle shaft wheel side cap: 0.2452 N (25 g) [0.0551 lb]
Rear wheel hub nut tightening torque: 107.87-147.10 N m (1100-1500 kg-cm)
• [79.59-108.53 ft-lb]
7-10
Point Operations
[Point 1]
Inspection: Inspect the rear axle hub preload.
Standard: 49 78 N (5 8 kg) [11 18 lb]
[Point 2]

8-2
GENERAL
Tilt steering
Steering valve
8-3
COMPONENTS
Steering wheel
4501
4501-0338
Steering post
4502
4502-146
8-4
Hydrostatic steering valve
4503
4503-018
8-5
Drag link & steering piping
4507
4507-122
8-6
Steering cylinder
4508
SPECIFICATIONS
8-7
HYDROSTATIC STEERING VALVE ASSY
REMOVAL- INSTALLATION
Removal Procedure
1 Remove the rear toe board.
2 Remove the front toe board.
3 Disconnect the piping.
4 Remove the hydrostatic steering valve ASSY.

8-8
DISASSEMBLY INSPECTION REASSEMBLY N m (kg-cm) [ft-lb]
Remove the fitting. [Point 1]
Remove the screw. [Point 2]
Remove the end cap and O-ring. [Point 3]
Remove the rotor set, spacer and O-ring. [Point 4]
Remove the drive, spacer, plate and O-ring. [Point 5]
Remove the retaining ring and gland bush seal. [Point 6]
Remove the needle bearing and bearing race.
Remove the spool and sleeve ASSY.
Remove the centering spring. [Point 7]

8-9
Point Operations
[Point 1]
Reassembly: Set the fitting in the correct position.
[Point 2]
Reassembly: Tighten the screws in the sequence illus-

trated at left.
[Point 3]
Reassembly: Set the concave portion of the rotor set star

in parallel.
[Point 4]
Reassembly: Insert the drive. For accurate positioning by

fitting the yoke and pin, mark a line with a
felt pin.
Reassembly: Confirm that A, B, C and D portions are par-

allel as illustrated at left.
[Point 5]
Disassembly:Remove the retaining ring with a straight-

edge screwdriver.
8-10
[Point 6]
Reassembly: Set springs back to back with the notched

portions at both ends facing downward.
8-11
STEERING WHEEL
Removal Procedure
Remove the horn button.
Remove the set screws, plate and spring.
Remove the steering wheel. [Point 1]

8-12
Point Operation
[Point 1]
Removal: SST 09609-20011

8-13
MAST JACKET ASSY
Removal Procedure
1 Remove the steering wheel. (See Steering Wheel Removal Installation on page 8-11.)
2 Remove the cover.
3 Remove the turn signal switch.
4 Remove the tilt lock lever.
5 Remove the combination meter.
6 Remove the direction switch.
7 Remove the tilt lock parts.
8 Remove the mast jacket ASSY.
8-14
1 Remove the snap ring.
2 Extract the main shaft.
3 Remove the snap ring.
4 Remove the steering post.
5 Remove the steering bracket.

8-15
STEERING CYLINDER ASSY
Removal Procedure
1 Remove the rear panel.
2 Remove the weight.
3 Remove the steering angle sensor. [Point 1]
5 Remove the steering cylinder ASSY.

8-16
Point Operation
[Point 1]
Installation: Install and adjust the steering potentio. See
page 2-50 for the adjustment method.
[Point 2]
Installation: Install and adjust the steering sensor.
1. While pushing the cylinder with a force of 98 N (10 kg) [22 lbl in the direction of G, eliminate the
backlash between the rack and pinion to 0.
2. While keeping the state above unchanged, temporarily tighten bolts (to about a half of the spec-
ified torque) in the order of A to D. Then retighten them to the specified torque.
(1)
Tightening torque for set blots A, B, C and D:
14710 to 16691 N m (1500 to 1700 kg-cm) (10853 to 12300 ft-lb)
3. Finally, tighten bolts E and F.

(2)
Method for tightening set bolts E and F:
Tighten each bolt by a half turn after it comes into contact with the boss end face on the
frame side.
Set by aligning the spring pin (on pinion side) and the punch mark (on rack side). (To obtain the tire
neutral position).
1 Remove the steering cylinder end.
2 Remove the piston.
3 Remove the bushing.
4 Remove the rack. [Point 1]
5 Remove the steering cylinder.
Note:
l Coat hydraulic oil on each part before reassembly.
l Use new O-rings, U-packings and dust seals at the time of reassembly.
Point Operation
[Point 1]
Inspection: Measure the steering cylinder bore.

Standard steering cylinder bore:
55 mm (2.17 in)
Steering cylinder bore wear limit:
55.35 mm (2.1791 in)
9-2
GENERAL
Dics brake
Brake mester cylinder

9-4
SPECIFICATIONS
COMPONENTS
Parking brake
9-4
Brake pedal
4701
9-6
Brake master cylinder
4702
Brake pipe
4714
9-6
Disc brake
9-7
DISC BRAKE
Removal Procedure
1 Remove the RR toe board and FR toe board.
2 Drain brake fluid.
3 Remove the disc brake LH.
4 Remove the steering wheel.

(See “Steering Wheel Removal.Installation” on page 8-11.)
5 Disconnect the drive motor LH wiring.
6 Remove the drive motor LH.

(See “Drive Motor Removal.Installation” on page 5-4.)
7 Remove the disc brake RH.

Note:
l Bleed air from the brake system.
l Check the brake fluid quantity and never fail to add if insufficient.
9-8
4 No. 1 and No. 2 separation

6 High pressure hose
7 Cap
8 Boot, piston
1 Remove the spring. [Point 1]
2 Remove the cotter pin, pin, lever ASSY No.3 and lever ASSY No.4
3 Remove the pad. [Point 2]
4 Separate lever ASSY No. 1 and lever ASSY No.2.
5 Remove the wheel cylinder.
6 Disconnect the high pressure hose.
7 Remove the wheel cylinder cap.
8 Remove the piston boot.
9 Remove the spring from the lever ASSY No.2.

9-9
Point Operations
[Point 1]
[Point 2]
Inspection: Inspect the pad thickness.
Wear limit: 1.0 mm (0.039 in)

9-10
DISC BRAKE ADJUSTMENT
1. Adjust the distance between pads by turning adjusting bolt 1 .

Distance between pads (c): Between 11 mm (0.433 in) and 12.2 mm (0.480 in) at the ends of
pads
2. Adjust the clearance between the brake wheel and each pad equally on the (a) and (b) sides by
turning adjusting bolt 2 .
Clearance: Between 0.4 mm (0.0157 in) and 1.1 mm (0.0433 in) at the ends of pads
3. Coat thread tightener at A portions after the end of adjustment.

9-11
BRAKE PEDAL
Removal Procedure
1 Remove the master cylinder pin.
2 Remove the set bolt.
3 Remove the brake pedal.

9-12
BRAKE PEDAL ADJUSTMENT
1 Adjust the brake pedal height by turning the adjusting bolt.
Brake pedal play (A): 135 ~ 140 mm (5.31 ~ 5.51 in)
2 Adjust the brake pedal play by means of the master cylinder clevis.
Brake pedal play (B): 10 3 mm (0.39 0.12 in).

9-13
MASTER CYLINDER
Removal Procedure
1 Drain brake fluid from the reservoir tank.
2 Disconnect the brake pipe and reservoir pipe.
3 Remove the cotter pin and washer pin.
4 Remove the master cylinder.
Note:
l Bleed air from the brake system.
l Check the brake fluid quantity, and add without fail if insufficient.
9-14
1 Remove the clevis.
2 Remove the boot.
3 Remove the snap ring, push rod and piston stop plate.
4 Remove the piston and spring.
5 Remove the master cylinder body.

9-15
PARKING BRAKE
Removal Procedure
1 Disconnect the parking brake wire. [Point 1]
2 Remove the parking brake ASSY.

9-16
Point Operations
[Point 1]
Adjustment: Adjust to 4 to 6 notches at the center of the lever when operated with a force of 294 N
(30 kg) [66 lb].
Check if the displacement of the A portion is within 3 mm (0.12 in), and make adjustment by means of
1 and 2 if the standard is not satisfied.
9-17
AIR BLEEDING FROM BRAKE SYSTEM
1. Bleed air from the master cylinder.
2. Bleed air from the wheel cylinder.
Note:
l While bleeding air from the brake system, be careful not to let the brake fluid in the reservoir tank
become insufficient.
l Always use genuine brake fluid (SAEJ-1703 DOT-3).
l While one person pumps the brake pedal several times and keeps it in the depressed state, another
person should loosen the breather plug for air bleeding until no bubble is seen in the discharged
brake fluid.
10-2
BODY FRAME
COMPONENTS
Frame & Weight
5101
10-3
Battery hood
5201
10-4
Instrument panel & floor

5301
10-5
BATTERY HOOD
2. Battery hood damper

3. Battery hood set bolts
Removal Procedure
1. Release the battery hood catch.
2. Disconnect the battery hood damper.
3. Remove the battery hood set bolts.
4. Remove the battery hood W/seat.

10-6
BALANCE WEIGHT
Removal Procedure
1. Remove the rear cover.
2. Temporarily hoist the balance weight with a wire rope.
3. Remove the set bolts.
4. Remove the balance weight.

10-7
COMBINATION METER
The combination meter has the diagnostic (self-diagnosis) function and analyzer (fault analysis) func-
tion in addition to general display such as the traveling speed, battery charge and hour meter indica-
tions.
10-8
1. Remove the cover sheet.
2. Remove the meter board.
3. Remove the panel ASSY.
4. Remove the window plate and glass.

11-2
NATURAL DROP TEST
1. Set the mast in the vertical position with the standard

load on the fork. Lift the fork by 1 to 1.5 m (40 to 60
in), and stop the motor.
2. Draw datum lines on the inner and outer masts, and

measure the drop in 15 minutes.
NATURAL FORWARD TILT TEST

load on the fork. Lift the fork about 50 cm (20 in) and
turn the key switch off.
2. Measure the tilt cylinder rod extension in 15 minutes.

11-3
OIL LEAK TEST
LIFT CYLINDER

load on the fork. Lift the fork by 1 to 1.5 m (40 to 60
in) and turn the key switch off.
2. Gently tilt the mast fully forward and turn the key switch
off. After 5 minutes, disconnect the oil control valve and
return hose. Measure the oil leakage amount in one
minute by placing a measuring cylinder at the fitting.
Standard oil leakage amount

(at lift port): 6 ~ 16 cc (0.37 ~ 0.98 in3)
NOTE:
If the natural drop is great though the oil leakage amount
is within the standard, the lift cylinder packing is
defective.
TILT CYLINDER

load on the fork. Lift the fork by about 50 cm (20 in)
and turn the key switch off.
2. After 5 minutes, disconnect the oil control valve and

return hose. Measure the oil leakage amount in 1 minute
by placing a measuring cylinder at the fitting.
Standard oil leakage amount

(total of lift and tilt): 14 ~ 34 cc (0.85 ~ 2.07 in3)
3. The leakage amount at the tilt port is the total leakage

at the lift port.
NOTE:
If the natural drop is great though the oil leakage amount
is within the standard. the lift cylinder packing is
defective.
12-2
V MAST ASSY
COMPONENTS
6101
12-3
6301
12-4
6302
6302-254
12-5
Removal Procedure
1 Disconnect the chain.
2 Remove the lift bracket.
3 Remove the hose cover.
4 Disconnect the overflow hose and high pressure hose.
5 Slightly suspend the mast with a hoist.
6 Remove the mast support cap.
7 Remove the tilt cylinder front pin. [Point 1]
8 Remove the V mast ASSY.
Note:
l Coat MP grease on the inner surfaces of the bushing and cap at the mast support and on the tilt
cylinder front pin before reassembly.

l It is necessary to inspect uneven motion of lift cylinders and make necessary adjustment when
any of the mast ASSY, outer mast, inner mast and lift cylinders is replaced (See page 12-31).
l Install the mast support bushing with the greasing port facing upward.
12-6
Point Operations
[Point 1]
Removal: SST 09810-20172-71
1 Hose cover
3 Disconnect the lift cylinder rod end.
4 Remove the lift cylinder.
5 Remove the lift roller.
6 Remove the mast strip.
7 Pull out the outer mast from the bottom side of the inner mast.

12-7
LIFT BRACKET
Note:
Remove the lift bracket before lift bracket roller replacement or shim adjustment.
1 Mast and fork

4 Inner mast
Removal Procedure
1 Set the mast in the neutral position and fully lower the fork.
2 Remove the lift bracket cotter pin.
3 Remove the nuts.
4 Lift the inner mast.

12-8
1 Remove the backrest.
2 Remove the lift rollers. [Point 1]
3 Remove the side rollers.
4 Remove the fork.
Point Operations
[Point 1]

12-9
CHAIN
Removal Procedure
1 Remove the adjusting nut and nut on the mast side.
2 Remove the chain wheel and chain.
3 Remove the cotter pin on the lift bracket side.
4 Remove the chain.
The installation procedure in the reverse of the removal procedure.
Note:
Tighten (in parallel) to prevent twisting as against the chain wheel.
12-10
Point Operation T = N m (kg-cm) [ft-lb]
[Point 1]
Installation:
1 Tighten adjusting nuts and .
2 Tighten adjusting nut .

12-11
CHAIN INSPECTION
1. Chain inspection
(1) Elongation
SST 09631-22000-71
Note:
When inspecting the chain elongation, use the SST
above and inspect without removal from the vehicle.
CHAIN ADJUSTMENT
1. Place the vehicle on a flat ground and set the mast in

the vertical position.
2. After moving the fork up and down several times without

a load, check that the chain tensions on the left and right
sides are equal.
3. Turn the adjusting nut (on the lift cylinder side) so that
the fork bottom surface is about to come into contact
with the ground surface without slackening the chain.
4. Check that the chain tensions are equal on the left and
right sides.
5. Check that the fork height is as specified.

12-12
FORK
REMOVAL
1. Raise the fork approximately 200 mm (7.88 in).
2. Place wooden stand under the fork rail slot.
3. Move each fork to the center.
4. Lower the fork to remove.
INSTALLATION
The installation procedure is the reverse of the removal

procedure.
INSPECTION
1. Fork inspection points
(1) Bending, crack, misaligned fork tips

Bending limit: 15 mm (0.59 in)
Fork end unevenness limit: 10 mm (0.39 in)
Note:
If the fork tips misalignment exceeds the maximum al-
lowance, check individual fork for bending, play at the
mounting section, and the warping of the lift bracket finger
bar.
12-13
MAST ADJUSTMENT
V SV MAST
Mast Lift Roller Adjustment (V SV)
1. Measure the gap with the mast overlap at near 500 mm (19.69 in).
2. Shift the inner mast to one side to bring the roller into contact with the outer mast. The gap on
the opposite side between the inner mast and the side of the roller at the position where they are
the closest shall be 0 to 0.8 mm (0 to 0.031 in).
3. See the table below for roller selection.

As a rule, use oversize rollers (No.2). Use No.1 rollers only when the mast inside width is small.
The roller size may be different between the left and right sides.
4. After the adjustment, the inner mast shall move smoothly in the outer mast.
Mast roller list

12- 14
1. Measure the gap with the mast overlap at near 500 mm (19.69 in)
2. Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust the
clearance between the roller and mast on the opposite side at the closest position to 0 to 0.8 mm
(0 to 0.031 in)
3. See the preceding page for the rollers to be used.
4. After the adjustment, check if the inner mast moves smoothly in the outer mast.
12-15
Lift Bracket Lift Roller Adjustment (V SV)
1. Make adjustment where the center of the side roller in the upper part of the lift bracket is 100 mm
(3.93 in) above the top end of the inner mast.
2. Upper lift rollers need no adjustment as they are fixed in position by snap rings.
3. For the center and lower lift rollers, shift the lift bracket to one side to bring the rollers into contact
with the mast, and adjust the clearance between the roller and mast on the opposite side to 0 to
0.8 mm (0 to 0.031 in) at the position where the roller is the closest to the mast.
4. Adjust the upper side rollers after adjusting the middle and lower rollers. Bring the side roller into
contact with the mast on one side, and adjust the clearance between the side roller and inner mast
to 0 to 0.6 mm (0 to 0.024 in).
5. After the end of adjustment steps 3 and 4, the lift bracket shall move smoothly along the overall
length of the mast.
12-16
Mast Strip Adjustment (V SV)
1. Make adjustment when the inner mast is fully lowered.
2. With the inner mast in contact with the outer mast roller, adjust the clearance between the mast
strip and mast to 0.5 to 1.0 mm (0.020 to 0.039 in)
3. After the adjustment, check if the mast moves smoothly.

12-17
SV Mast Assy
Components
6101
6101-368
12-18
6302
6302-237
12-19
FV MAST
Components
6101
6101-367
12-20
6302
6302-235
12-21
Outer Mast and Inner Mast Roller Adjustment (FV)
1. Shift the inner mast to one side to bring the roller into contact with the outer mast. The gap on
the opposite side between the roller and outer mast at the position where they are the closest shall
be 0 to 0.5 mm (0 to 0.020 in).
2. Turn the bolt for adjustment, and lock the bolt by the nut when the gap is adjusted to an appropri
ate level. The mast gap, however, shall be even on the left and right sides.
3. See the roller list for roller selection. As a rule use oversize rollers (No.2). Use No.1 rollers only
when the mast inside width is small.
5. See the table below for the mast overlap at the time of adjustment.
Inner mast roller list

12-22
Inner Mast and Outer Mast Roller Adjustment (FV)
1. See the table on the preceding page for the mast overlap at the time of adjustment.
2. Shift the inner mast to one side to bring the roller into contact with the mast. The gap on the oppo-
site side between the roller side face and mast at the position where they are the closest shall be
0 to 0.5 mm (0 to 0.020 in).
3. Turn the bolt for adjustment. When the appropriate gap is obtained, lock the bolt by the nut.
4. See the list below for the roller to be used.
Outer mast roller list
Bottom recessed roller adjustment
If the bottom recessed roller bolt is overtightened to obstruct smooth mast or lift bracket movement,
loosen the nut and return the bolt a little.
Make readjustment after moving the mast or lift bracket a few times.
As the roller does not retract by loosening of the bolt only, always move the mast or lift bracket a few
times before making readjustment.
12-23
Lift Bracket Roller Adjustment (FV)
1. Make adjustment with the center of the lift bracket upper side roller at 100 mm (3.9 in) from the
top of the inner mast.
2. The upper and center lift rollers need no adjustment because they are stopped by snap rings.
3. For the lower lift rollers and side rollers, shift the lift bracket to one side to bring the roller into
contact with the mast, and make shim adjustment for a clearance of 0 to 0.5 mm (0 to 0.020 in)
between the mast and the roller on the opposite side where the roller is the closest.
4. After the adjustment, check for smooth movement of the lift bracket.
12-24
Mast Strip Adjustment (FV)

12-25
FSV MAST
Components
6101
6101-366
12-26
6302
6302-236
12-27
Outer Mast and Middle Mast Lower Roller Adjustment (FSV)
Middle Mast and Inner Mast Adjustment (FSV)
1. Shift the middle mast to one side to bring the roller into contact with the mast. The gap on the
opposite side between the roller side face and mast at the position where they are the closest shall
be 0 to 0.5 mm (0 to 0.020 in).
The mast gap, however, shall be even on the left and right sides.
3. See the roller list for roller selection.

As a rule, use oversize (No.2) rollers. Use No.1 rollers only when the mast inside width is small.
4. After the adjustment, the inner mast shall move smoothly in the middle mast.
5. See the table below for the mast overlap at the time of adjustment.
12-28
Middle Mast and Outer Mast Rollers Adjustment (FSV)

Inner Mast and Middle Mast Upper Rollers Adjustment (FSV)
1. See page 12-27 for the mast overlap at the time of adjustment.
2. Shift the middle mast to one side to bring the roller into contact with the mast. The gap on the
opposite side between the mast roller side face and mast at the position where they are the closest
shall be 0 to 0.5 mm (0 to 0.020 in).
The mast gap, however, shall be even on the left and right sides.
4. See the table below for the roller to be used.
Outer mast upper roller
Bottom recessed roller adjustment

If the bottom recessed roller bolt is overtightened to obstruct smooth mast or lift bracket movement,
loosen the nut and return the bolt a little.
Make readjustment after moving the mast or lift bracket a few times.
As the roller does not retract by loosening of the bolt only, always move the mast or list bracket a few
times before making readjustment.
12-29
Lift Bracket Lift Roller Adjustment (FSV)
1. Make adjustment with the lift bracket fully raised.
2. Upper lift rollers need no adjustment as they are stopped by snap rings.
3. For lower lift rollers and side rollers, shift the lift bracket to one side to bring the roller into contact
with the mast, and make shim adjustment for a clearance of 0 to 0.5 mm (0 to 0.020 in) between
the roller and mast on the opposite side where the roller is the closest.
4. After the adjustment, check for smooth movement of the lift bracket.
12-30
Mast Strip Adjustment (FSV)

12-31
LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN

LIFTING)
Note:
For double lift cylinders, inspection and adjustment are required to prevent uneven lifting on the left
and right sides due to tolerances of parts.
The inspection and adjustment must be made whenever any of the following parts is replaced:
Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-
ASSY, and inner mast SUB-ASSY.
1. Inspection
Slowly raise the inner mast, and observe the stopping
states of the left and right cylinder rods at the moment
when the inner mast reaches the maximum height.
(1) Normal case
Both the left and right rods stop almost simultaneously
with almost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of the
inner mast shakes at the time of stopping. To correct
this, add shims to the cylinder that stops first.
2. Adjustment method
(1) Raise the inner mast, Set the SST to the outer mast
tie beam, and lower the inner mast until it reaches the
SST.
SST 09610-22000-71
(2) Remove the set bolt of the cylinder rod end on the side
requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims on the cylinder rod end. Slowly raise the
cylinder rod into the inner mast.
(5) Fix the set bolt of the cylinder rod end.
(6) Raise the inner mast for reinspection.
(7) Repeat the inspection and adjustment until the num-
ber of shims is determined.
Shim thickness:
0.5 mm (0.020 in)
1.0 mm (0.039 in)
12-32
V MAST ASSY
COMPONENTS
6101
12-33
6301
12-34
6302
12-35
Removal Procedure
1 Set the mast vertical and lower the fork to the bottom position.
2 Disconnect the chain.
3 Remove the chain wheel. [Point 1]
4 Remove the lift bracket. (Raise the inner mast until it comes off from the lift bracket, and slowly
move the vehicle in the reverse direction to depart from the lift bracket. Then stop the engine.)
[Point 2]
5 Disconnect the overflow hose and high pressure hose. (Lower the inner mast to the bottom posi-
tion and operate the lift lever several times to release the residual pressure in the lift cylinder be-
fore disconnecting the hoses.)
6 Slightly hoist the mast.
7 Remove the mast support caps.
8 Remove the tilt cylinder front pin. [Point 3]
9 Remove the mast ASSY.

12-36
Note:
• Apply MP grease on the interior surface of the mast support bushing, inner surface of the mast sup-
port cap and tilt cylinder front pin.
• Mast support cap set bolt tightening torque:
T = 68.65 107.87 N m (700 1100 kg-cm) [50.65 79.59 ft-lb]
• If any of the mast ASSY, outer mast, inner mast and lift cylinder is replaced, it is necessary to in-
spect and adjust uneven motion of the lift cylinder. See the lift cylinder rod shim adjustment section
(on page 12-68) for the inspection and adjustment method.
• Adjust the chain tension. (See page 12-49.)
Point Operations
[Point 1]
Removal: Use the SST for removal if the fitting is tight.

SST 09950-20017
Installation: Install the chain wheel with its side having

greater radius at the periphery of its hole fac-
ing the boss of the mast side pin.
[Point 2]
Installation: Adjust the eccentric roller (OPT) after lift
bracket installation. (Common to the V and
SV masts.)
1. Turn the eccentric roller pin in the direction shown in

the illustration, and lock with the set nut at the posi-
tion where the roller comes into contact with the inner
mast.
The direction for turning the pins on the left and right
sides are the same as illustrated.
2. The pin on the right side is punched with punched “R”

mark while the one on the left side has no mark.
3. As the pin on the right and left sides use lefthand

screw and righthand screw, respectively, the set nut
tightening direction is the same as the roller pin turning
direction in step 1 above.
12-37
[Point 3]
Removal: SST 09810-20172-71
12-38
MAST DISASSEMBLY INSPECTION REASSEMBLY
2 Disconnect the overflow hose and high pressure hose.
3 Remove the cylinder rod end set bolt and disconnect the rod end. [Point 1]
4 Remove the cylinder support. [Point 2]
5 Remove the cylinder bottom set bolts and remove the lift cylinder.
6 Slide the inner mast in the lowering direction and remove the lift rollers.
7 Remove the mast strip. [Point 3]
8 Remove the outer mast.

12-39
Point Operations
[Point 1]
Disassembly: Shim adjustment has been made at the lift

cylinder rod end for prevention of cylinder
Funeven motion between the left and right
sides. Take a note on which side the shim
adjustment is made and the number of
shims used.
[Point 2]
Disassembly: Take a note on the number of cylinder su-
port shims used.
Reassembly: When the mast or cylinder is replaced, make

shim adjustment at the cylinder support.
With the cylinder rod end inserted to the in-
ner mast, eliminate the clearance between
the cylinder support and outer mast by in-
serting shims. The shim thickness should be
slightly thicker.
[Point 3]
Inspection: Measure the mast strip thickness.
Thickness limit: 1.5 mm (0.059 in)

12-40
LIFT BRACKET DISASSEMBLY INSPECTION REASSEMBLY
1 Remove the lift rollers. [Point 1]
2 Remove the side rollers. [Point 2]
3 Remove the eccentric rollers (OPT). [Point 3]
4 Remove the back rest.
Note:
Back rest set bolt tightening torque T = 99.54 ~ 184.86 N m (1015 ~ 1885 kg-cm) [73.44 ~
136.38 ft-lb]
12-41
Point Operations
[Point 1]
[Point 2]
Reassembly: Do not mistake the side roller mounting di-

rection.
The side where the chamfering radius of the
roller outer circumference shall face the
front side.
[Point 3]
Disassembly: The eccentric roller pin set nuts use

lefthand screw on the right side and right-
hand screw on the right side.
Reassembly: Install the eccentric roller pin punched with

the “R” mark on the right side and the one
without a punch mark on the left side.
Reassembly: Keep the eccentric roller pin set nuts not

tightened here and adjust the eccentric roll-
ers after installing the lift bracket on the ve-
hicle.
12-42
MAST ADJUSTMENT (V MAST)
Mast Lift Roller Adjustment
1. Inner mast roller clearance adjustment

(1) Measure the clearance with the mast overlap at near
450 mm (17.72 in).
(2) Shift the inner mast to one side to bring the roller
into contact with the outer mast, and adjust the
clearance between the roller side face and mast at
the closest position on the opposite side to the fol-
lowing value by inserting the inner mast roller shim.
Standard clearance A = 0 0.8 mm

(0 0.031 in)
Shim thickness: 0.5 and 1.0 mm
(0.020 and 0.039 in)
(3) Distribute the shim thickness equally to the left and

right rollers. (See the “mast roller removal installa-
tion” section for the shim replacement procedure.)
(4) After the adjustment, check that the inner mast
moves smoothly in the outer mast.
12-43
2. Outer mast roller clearance adjustment

(1) Measure the clearance with the mast overlap at near
450 mm (17.72 in).
(2) Shift the inner mast to one side to bring the roller
into contact with the outer mast, and adjust the
clearance between the roller side face and mast at
the closest position on the opposite side to the fol-
lowing value by inserting the outer mast roller shim:
Standard clearance B = 0 0.8 mm

(0 0.031 in)
(0.020 and 0.039 in)
(3) Distribute the shim thickness equally to the left and

right sides. (See the “mast roller removal install-
tion” section for the shim replacement procedure.)
(4) After the adjustment, check that the inner mast
moves smoothly in the outer mast.
12-44
Mast Roller Removal installation
1. Remove the lift bracket. (See the mast ASSY removal

procedure steps 1 to 4 on page 12-35.)
2. Jack up the vehicle and support the tires with wooden
blocks. Lock the front and rear tires to prevent rota-
tion.
3. Tilt the lift cylinder.

(1) Remove the hose cover at the bottom of the mast
and disconnect the lift cylinder hose on the LH side.
(2) Remove the lift cylinder bottom set bolts.
(3) Sling the inner mast upper tie beam with a wire and
slightly hoist it.
(4) Remove the lift cylinder rod end set bolts, and dis-
connect the rod end by hoisting the inner mast.
(5) Remove the lift cylinder support.
(6) Tile the lift cylinders LH and RH and tie them with
ropes to the outer mast tie beam.
4. Remove the mast rollers.

(1) Lower the hoisted inner mast slowly until mast roll-
ers are visible, and support the bottom with wooden
blocks.
(2) Remove the inner mast rollers and shims.
(3) Remove the outer mast rollers and shims.
5. The installation procedure is the reverse of the removal

procedure.
12-45
Lift Bracket Roller Adjustment
1. Lift roller and side roller clearance adjustment

(1) Measure the clearance when the center of the lift
bracket upper side roller is 100 mm (3.93 in) from
the top of the inner mast.
(2) The upper lift rollers need no adjustment because
they are fixed by snap rings.
(2) Measure the clearances at the middle and lower lift
rollers after removing the side rollers.
Shift the lift bracket to one side to bring the roller
into contact with the inner mast, and measure the
clearance between the roller side face and the mast
at the closest position on the opposite side to the
following value by inserting the lift roller shim.
Standard clearance C = 0 0.8 mm

(0 0.031 in)
(0.020 and 0.039 in)
12-46
(4) Distribute the shim thickness equally to the left

and right sides. (For the shim replacement pro-
cedure, see the lift bracket disassembly section
on page 12-40.)
(5) Install the side rollers.
(6) Side roller adjustment shall be made after adjusting

the middle and lower lift rollers.
Bring the side roller on one side into contact with the
mast side surface, and make adjustment by shim in-
sertion to make the clearance between the side
roller and inner mast side surface on the opposite
side satisfy the following standard.
Standard clearance D = 0 0.6 mm

(0 0.024 in)
(0.020 and 0.039 in)
(7) The shim thickness shall be distributed equally in-

to the left and right sides. (Shim replacement is
possible on the vehicle. For the side roller installa-
tion, see the lift bracket disassembly section on
page 12-40.)
2. After the adjustment, the lift bracket should move

smoothly along the overall mast length.
12-47
Mast Strip Adjustment
1. Mast strip clearance adjustment

(1) Measure the clearance with the inner mast at the
bottom position.
(2) With the inner mast in contact with the outer mast
roller, adjust the clearance between the mast strip
and inner mast to the following value by inserting
the mast strip shim. (The shim replacement pro-
cedure is the same as that described in the ‘’mast
roller removal installation” section on page 12-
44.)
Standard clearance E = 0.5 1.0 mm

(0.020 0.039 in)
Shim thickness: 0.5 and 1.0 mm (0.020 and
0.039 in)
(3) After the adjustment, the mast should move

smoothly.
12-48
CHAIN
INSPECTION
1. Inspect the chain elongation.

SST 09631-22000-71
Note:
• When inspecting the chain elongation, use the SST
above and inspect without removal from the vehicle.
• Standard chain link pitch
15.88 mm (0.6252 in) (Type: BL534)
REASSEMBLY
Chain Adjusting Nut Tightening Sequence
1 Tighten nuts and

..Tightening torque T = 49.03 ~ 78.45 (500 800 kg-cm)
[36.18 ~ 57.88 ft-lb]
2 Tighten nut .
12-49
ADJUSTMENT
Place the vehicle on a flat ground, and set the mast in the vertical position.
After moving the fork up and down several times without a load, check that the chain tension on
the left and right sides are equal.
Turn the adjusting nut so that the fork bottom surface is about to come into contact with the
ground surface without slackening the chain.
Check the chains for equal tension on the left and right sides.
Check that the chains are not twisted.
Check that the maximum fork height is as specified.
FORK
REMOVAL
1. Loosen the set bolts (OPT) for preventing the fork from
loosening.
Note:
Always set the lever for preventing the fork from loosening
in the horizontal position after it is used.
2. Position the fork at 20 cm (7.9 in) above the ground.
3. Place a wooden block under the notched portion of the

fork rail.
4. Unlock after lifting the fork stopper pin, and shift the
fork blades one by one to the center.
5. Gradually lower the fork and remove it.
INSTALLATION
The installation procedure is the reverse of the removal pro-

cedure.
INSPECTION
1. Inspect the fork.
Fork tip end limit misalignment: 10 mm (0.39 in)
Note:
If the tip end limit misalignment is exceeded, inspect the
bend, fork mounting looseness and lift bracket finger bar
distortion for each blade.
12-50
SV MAST ASSY
COMPONENTS
6101
12-61
6302
12-52
MAST ADJUSTMENT (SV MAST)

Mast Lift Roller Adjustment (SV)
1. Inner mast roller clearance adjustment

(1) Measure the clearance with the mast overlap at near 450 mm (17.72 in).
(2) Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust
the clearance between the roller and mast at the closest position on the opposite side to the
following value by inserting the inner mast roller shim.
Standard clearance A = 0 ~ 0.8 mm (0 ~ 0.031 in)

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) Distribute the shim thickness equally to the left and right rollers.
(4) After the adjustment, check that the inner mast move smoothly in the outer mast.
12-53

the clearance between the roller side face and mast at the closest position on the opposite side
to the following value by inserting the outer mast roller shim.
Standard clearance B = 0 0.8 mm (O 0.031 in)

(3) Distribute the shim thickness equally to the left and right sides. (See the mast roller removal
installation section for the shim replacement procedure.)
(4) After the adjustment, check that the inner mast moves smoothly in the outer mast.
12-54
Lift Bracket Roller Adjustment (SV)

(1) Measure the clearance when the center of the lift bracket upper side roller is 100 mm (3.94 in)
from the top of the inner mast.
(2) The upper and lower lift rollers need no adjustment because they are fixed by snap rings.
(3) Adjust the clearances at the middle lift rollers as follows: Shift the lift bracket to one side to
bring the roller into contact with the inner mast, and adjust the clearance between the roller
side face and the mast at the closest position on the opposite side to the following value by
inserting the lift roller shim.
Standard clearance C = 0 0.8 mm (0 0.031 in)

(4) Distribute the shim thickness equally to the left and right sides.
(5) Adjust the upper and lower side rollers after adjusting the middle lift rollers. Bring the side roller
on one side into contact with the mast side surface and adjust the clearance between the side
roller and inner mast surface to the following value by inserting the side roller shim.
Standard clearance D = 0 0.6 mm (0 0.024 in)

(6) Distribute the shim thickness equally to the left and right side rollers.
2. After the adjustment, the lift bracket should move smoothly along the overall mast length.
12-55
Mast Strip Adjustment (SV)

(1) Measure the clearance with the inner mast at the bottom position.
(2) With the inner mast in contact with the outer mast roller, adjust the clearance between the
mast strip and inner mast to the following value by inserting the mast strip shim.
Standard clearance E = 0.5 1.0 mm (0.020 0.039 in)

(3) After the adjustment, the mast should move smoothly.

12-56
FV MAST ASSY
COMPONENTS
6101
6101-382
6302
6302-269
12-58
MAST ADJUSTMENT (FV MAST)
Mast Lift Roller Adjustment (FV)
1. Inner mast roller clearance adjustment (FV)

to the following value by inserting the inner mast roller shim.
Standard clearance A = 0 0.8 mm (0 0.031 in)

Shim thickness: 0.5 and 1.0 mm 0.020 and 0.039 in)
12-59

to the following value by inserting the outer mast roller shim:
Standard clearance B = 0 0.8 mm (0 0.031 in)

12-60
Litt Bracket Roller Adjustment (FV)

(1) Measure the clearance when the center of the lift bracket upper side roller is 100 mm (3.94 in)
from the top of the inner mast.
(2) The upper and middle lift rollers need no adjustment because they are fixed by snap rings.
(3) For the lower lift roller, shift the lift bracket to one side to bring the roller into contact with the
inner mast, and adjust the clearance between the roller side face and the mast at the closest
position on the opposite side to the following value by inserting the lift roller shim.

(5) Adjust the side rollers after adjusting the lower lift rollers. Bring the side roller on one side into
contact with the mast side surface and adjust the clearance between the side roller and inner
mast on the opposite side to the following value by inserting the side roller shim:
Standard clearance D = 0 0.6 mm (0 0.024 in)

(6) Distribute the shim thickness equally to the left and right side rollers.
After the adjustment, the lift bracket should move smoothly along the overall mast length.
2.
12-61
Mast Strip Adjustment (FV)

(1) Measure the clearance with the inner mast at the bottom position.
(2) With the inner mast in contact with the outer mast roller, adjust the clearance between the
mast strip and inner mast to the following value by inserting the mast strip shim.

(3) After the adjustment, the mast should move smoothly.

12-62
FSV MAST ASSY
COMPONENTS
6101
6101-380
12-63
6302
12-64
MAST ADJUSTMENT (FSV MAST)
Mast Lift Roller Adjustment (FSV)
1. Inner mast roller and middle mast lower roller clearance adjustment
(2) Shift the inner mast to one side to bring the roller into contact with the outer mast and the mid-
dle mast, and adjust the clearance between the roller side face and mast at the closest position
on the opposite side to the following value by inserting the inner mast roller shim and middle
mast lower roller shim, respectively.
Standard clearance A = 0 0.8 mm (0 0.031 in)

(4) After the adjustment, check that the inner mast moves smoothly in the middle mast, and the
middle mast moves smoothly in the outer mast.
12-65
2. Outer mast roller and middle mast upper roller clearance adjustment
(2) Shift the inner mast to one side to bring the roller into contact with the inner mast and middle
mast, and adjust the clearance between the roller and mast at the closest position on the op-
posite side to the following value by inserting the outer mast roller shim and middle mast upper
roller shim respectively.
Standard clearance B = 0 0.8 mm (0 0.031 in)

(4) After the adjustment, check that the inner mast moves smoothly in the middle mast and the
middle mast moves smoothly in the outer mast.
12-66
Lift Bracket Roller Adjustment (FSV)

(1) Measure the clearance with the lift bracket at the uppermost position.
(2) The upper lift rollers need no adjustment because they are fixed by snap rings.
(3) For the lower lift rollers, shift the lift bracket to one side to bring the roller into contact with the
inner mast, and measure the clearance between the roller side face and the mast at the closest
position on the opposite side to the following value by inserting the lift roller shim.

(5) Adjust the side rollers after adjusting the lower lift rollers.
Bring the side roller on one side into contact with the mast side surface, and adjust the clear-
ance between the side roller and inner mast side surface to the following value by inserting the
side roller shim:
Standard clearance D = 0 ~ 0.6 mm (0 ~ 0.024 in)

Shim thickness : 0.5 and 1.0 mm (0.020 ~ 0.039 in)
2. After the adjustment, the lift bracket should move smoothly along the overall mast length.
12-67
Mast Strip Adjustment (FSV)

(1) Measure the clearance with the inner mast or middle mast at the bottom position.
(2) With the inner mast in contact with the middle mast upper roller, adjust the clearance between
the mast strip and inner mast to the value shown below by inserting the mast strip shim.
Then, with the middle mast in contact with the outer mast roller, adjust the clearance between
the mast strip and the middle mast to the value shown below by inserting the mast strip shim.

Shim thickness: 0.5 and 1.0 mm (0.020 0.039 in)
After the adjustment, the mast should move smoothly.

(3)
12-68
LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN)

LIFTING)
Note:
• For double lift cylinders, inspection and adjustment are required to prevent uneven lifting on the left
and right sides due to tolerances of parts, etc.
• The inspection and adjustments must be made whenever any of the following parts is replaced:
Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast
SUB-ASSY, and inner mast SUB-ASSY
1. Inspection method
Slowly raise the inner mast, and observe the stopping
states of the left and right cylinder rods at the moment
when the inner mast reaches the maximum height.
(1) Normal case
Both the left and right rods stop almost simulta-
neously with almost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of
the inner mast shakes at the time of stopping. To
correct this, add shims to the cylinder that stops
first.
2. Adjustment method
(1) Raise the inner mast, set the SST to the outer mast
tie beam, and lower the inner mast until it reaches
the SST.
SST 09610-22000-71
(2) Remove the set bolt of the cylinder rod end on the
side requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims on the cylinder rod end. Slowly raise the
cylinder rod end into the inner mast.
(5) Fix the set bolt of the cylinder rod end.
(6) Raise the inner mast for reinspection.
(7) Repeat the inspection and adjustment until the num-
ber of shims is determined.
Shim thickness:
0.5 and 1.0 mm (0.20 and 0.039 in)
13-2
LIFT CYLINDER ASSY (1993.1 1994.1)
GENERAL
SPECIFICATIONS
13-3
COMPONENTS
6501
13-4
Removal Procedure
1 Remove the chain and chain wheel.
3 Disconnect the cylinder rod end, and set the SST. [Point 1]
5 Remove the lift cylinder ASSY.
Note:
• Adjust the lift chain tension equally on the left and right sides.
• Repeat full stroke lifting and lowering without any load to bleed the air and check if movements are
normal.
• After the movement check, inspect the hydraulic oil level.
• If a part of the lift cylinder ASSY, etc. is replaced, it is necessary to check and adjust uneven move-
ments of lift cylinders. See page 12-31 for the inspection and adjustment methods.
13-5
Point Operations
[Point 1]
Removal: SST 09610-22000-71

13-6
1 Overflow hose
1 Remove the overflow hose.

2 Remove the lift cylinder cover.
3 Remove the cylinder rod. [Point 1]
4 Remove the rod guide.
5 Remove the wear ring, back up ring and U packing.
6 Remove the flow regulator valve ASSY.
7 Remove the safety down valve ASSY.
8 Remove the lift cylinder. [Point 2]
Note:
• Before reassembly, coat hydraulic oil on each part.
• Replace O-rings, U-packing and dust seals with new ones at the time of reassembly.
• Coat liquid packing (08833-00080) on the threaded portion of the cylinder cover before reassembly.
13-7
Point Operations
[Point 1]
Inspection: Measure the piston rod outside diameter.

Standard outside diameter: 35 mm (1.38 in)
Inspection: Measure the bend of the piston rod.

Piston rod bend limit: 2.0 mm (0.079 in)
[Point 2]
Inspection: Measure the tilt cylinder bore.

Standard bore: 45 mm (1.77 in)
13-8
TILT CYLINDER
GENERAL
SPECIFICATIONS
13-9
COMPONENTS
6511
13-10
1 Slightly hoist the mast
Removal Procedure
1 Slightly hoist the mast.
2 Remove the front pin [Point 1]
3 Disconnect the hose.
4 Remove the rear pin.
5 Remove the tilt cylinder.
Note:
l Check if the rod joint length is the same as that at the time of removal.
l Raise the fork by approx. 200 mm (7.87 in). Inspect and adjust the forward/backward tilt angle.
l Put a match mark (with red paint) on the joint and rod.
l Slowly tilt the mast a few times to check movement.
l Check the hydraulic oil level, and add if insufficient.
l Coat MP grease where the front and rear pins are inserted.
l Tilt the mast fully forward and backward to confirm no uneven movements between the left and right
sides.
13-11
Point Operations
[Point 1]
Removal: SST 09810-20172-71

13-12
DISASSEMBLY . INSPECTION . REASSEMBLY T = N m (kg-cm) [ft-lb]
1 Loosen the rod guide, and extract the rod w/ piston. [Point 1]
2 Remove the guide.
3 Remove the piston.
4 Remove the rod. [Point 2]
5 Remove the cylinder. [Point 3]
Note:
l Coat hydraulic oil on each part before reassembly.
l Replace O-rings, U-packings and dust seals with new ones at the time of reassembly.
l Coat liquid packing (08833-00080) on the threaded portion of the cylinder cover.
l When installing the rod guide, wrap the threaded portion of the piston rod thinly with vinyl tape and
slowly insert the rod to prevent sealing parts from being damaged.
13-13
Point Operations
[Point 1]
Disassembly Reassembly: SST 09620-10110-71
[Point 2]
Standard piston rod outside diameter:
30.00 mm(1.1811 in)
Piston rod wear limit:
29.92 mm (1.1780 in)

Piston rod bend limit:
1.0 mm (0.039 in)
[Point 3]

Standard tilt cylinder bore:
70.0 mm (2.756 in)
Tilt cylinder bore wear limit:
70.35 mm (2.7697 in)
13-
13-15
6501
13-16
Removal Procedure
1 Remove the lift bracket. (See removal procedure steps 1 to 4 in mast removal-installation section
on page 12-35.)
2 Remove the cylinder rod end set bolt and cylinder bottom set bolt.
3 Disconnect the cylinder rod end. [Point 1]
5 Disconnect the hose.
6 Remove the lift cylinder support. [Point 2]
7 Remove the lift cylinder ASSY.
Note:
Perform the following operations after installing the lift cylinder:
l Repeat lifting and lowering to stroke ends without load to bleed the air and to check normal opera-
tion.
l After the operation check, check the hydraulic oil level and add oil if insufficient.
l Inspect the lift cylinders for uneven movements and make adjustment if necessary. (See the lift
cylinder rod shim adjustment section on page 12-68.)
13-17
Point Operations
[Point 1]
Removal: Hoist the inner mast (middle mast) and set the
SST to the inner mast (middle mast) tie beam.
SST 09610-22000-71
Removal: Shim adjustment is made at the lift cylinder rod

end to prevent uneven movements of the lift
cylinders RH and LH. Take a note on which side
the adjustment is made and the number of
shims used.
[Point 2 ]
Installation: The cylinder support shall be tightened tem-
porarily here and make shim adjustment
after rod end connection
Adjustment: With the rod end connected, insert shims be-

tween the cylinder support and outer mast to
eliminate the clearance. The shim thickness
shall be slightly on the thicker side.
13-18

Note:
l Oil will leak if the U packing or dust seal at the rod guide portion is defective.
l Natural drop will occur if the U packing at the piston portion is defective.
Disassembly the cylinder cover.
1 Remove the cylinder cover.
2 Remove the rod guide.
3 Remove the piston rod. [Point 11
4 Remove seals from the piston side.
5 Remove the flow regulator valve or safety down valve.
6 Remove the lift cylinder. [Point 2]
Note:
l Do not install dry parts but apply hydraulic oil before reassembly.
l Apply liquid packing 108833-00080) on the threaded portion of the cylinder cover before tightening.
l Cylinder cover tightening torque T = 284.39 ~ 421.69 N m 12900 ~ 4300 kg-cm) 1209.82 ~ 311.11
ft-lb]
13-19
Point Operations
[Point 1]

Standard outside diameter: 35 mm (1.38 in)

Piston rod bend limit: 2.0 mm (0.079 in)
[Point 2]

Standard bore: 45 mm (1.77 in)
14-2
OIL PUMP ASSY
GENERAL
SPECIFICATIONS
14-3
COMPONENTS
6701
14-4
.
Removal Procedure

2 Remove the RR panel.
3 Remove the panel.
4 Disconnect the inlet hose and high pressure hose.
5 Disconnect the motor wiring.
6 Hoist the motor slightly. [Point 1]
7 Remove the motor w/ oil pump.
8 Disconnect the motor and oil pump.
Note:
l Coat paste lubricant containing molybdenum disulfide on the pump spline before installation.
l Clean the surface for mounting the fitting to prevent damage on the O-ring.
Point Operations
14-5
1 Remove the cover. [Point 1]
2 Remove the mounting flange.
3 Remove the backing ring, bushing seal and body seal.
4 Remove the gear & bushing set. [Point 2]
5 Remove the oil seal.
6 Remove the body. [Point 3]
Note:
l Wash the parts, blow them with compressed air and reassemble them after applying hydraulic oil.
l Always use new seals after disassembly.
4-6
Point Operations
[Point 1]
Disassembly: Put a match mark.
[Point 2]
Inspection: Measure the body bore.
Limit: 39.180 mm (1.54252 in)
Inspection: Measure the flaw on the body inside surface.
Flaw depth limit: 0.1 mm (0.004 in)
Inspection: Measure the side bushing bore.
Limit: 19.123 mm (0.75287 in)
Inspection: Measure the bushing length in axial direction.
Limit: 14.77 mm (0.5815 in)
Inspection: Measure the center bushing bore.
Limit: 19.123 mm (0.75287 in)
Inspection: Measure the center bushing length in axial

direction.
Limit: 29.68 mm (1.1685 in)
Inspection: Measure the gear shaft outside diameter
Limit: 18.935 mm (0.74547 in)

14-7
[Point 3]
Inspection: Measure the gear contact trace on the suction

side body inner surface.
Limit:
Contact trace exceeding half of the circum-
ference
14-8
TEST PROCEDURE
Note:
A bench test is required for a strict inspection, but it is impossible in an actual service. Install the oil
pump on the actual vehicle and judge the properness of the oil pump state by checking the cylinder
operation.
1. Check on the display if the battery charge is sufficient.

2. Check if the oil control valve relief pressure is as specified.
3. Raise the hydraulic oil temperature to 50-55 C (122-131 F), and measure the lift cylinder full stroke
operation time calculate the lifting speed.
Lifting Speed Table

V SV Masts Unit: mm/sec (fpm)
14-9
POWER STEERING PUMP ASSY
GENERAL
SPECIFICATIONS
COMPONENTS
4510
14-10
2 Rear tor board - front tor board
Removal Procedure
1 Remove the side cover RH.
2 Remove the rear tor board and front tor board.
3 Disconnect the power steering motor wiring.
4 Disconnect the suction hose.
6 Remove the power steering motor W/power steering pump.
7 Disassemble the power steering motor and power steering pump.
Note:
Coat paste lubricant containing molybdenum disulfide on the oldham joint before installation.
15-2
GENERAL
Oil Control Valve Sectional View (in Neutral State)

15-3
SPECIFICATIONS
‘
HYDRAULIC CIRCUIT
15-4
COMPONENTS
6705
15-5
OIL CONTROL VALVE ASSY
1 Rear toe board and front toe board
Removal Procedure
1
4 Remove the pin.
Remove the oil control valve ASSY.

•

•
• Note:
Check the hydraulic oil level, and add oil to the specified level if insufficient.
Coat grease on the oil control valve lever link.
15-6
Note:
• Select a clean location for operation.
• As every component part is finished with high precision, carefully operate during disassembly to pre-
vent any damage.
T = N m (kg-cm) [ft-lb]
Remove the seal holder.
1 Remove the spring cover.
2 Remove the lift spool and tilt spool.
3 Disassembly the lift spool and tilt spool. [Point 1]
4 Remove the tilt relief valve.
5 Remove the lift relief valve.
6 Remove the check plunger.
7 Remove the outlet housing.
8 Remove the valve seat.
9
Note:
Before reassembly, thoroughly wash each part, blow compressed air and coat hydraulic oil.
15-7
Point Operations
[Point 1]
Disassembly: SST 09610-10160-71

15-8
RELIEF PRESSURE ADJUSTMENT
Note:
• Always make adjustment according to the following procedure. Random adjustment may generate
a high pressure to damage the oil pump and other hydraulic equipment.
• No adjustment is required when the relief valve is not disassembled or is replaced with a new one.
Remove the plug (9/16 - 18UNF-2B) on top of the oil control valve, and install an oil pressure gauge.
Oil pressure gauge: Pressure resistance at 19610 kPa (200 kg/cm2, 2840 psi) or more.
Loosen the lift relief valve adjusting screw.

Loosen the lock nut, and loosen the adjusting screw to a degree not coming off from the body.
Adjust the hydraulic pressure.

Turn the key switch to ON.
Set the lift lever slowly to the lift position, and tighten the adjusting screw gradually before the
fork starts to rise.
Lift the fork fully to the maximum height, and read the hydraulic pressure at the position. Tight-
en the adjusting screw so that the pressure at the time becomes normal.
Tighten the lock nut and check the hydraulic pressure again.
Adjust the tilt relief valve hydraulic pressure.
Note:
• Follow the same procedure as that for lifting.
• Tilt the mast fully backward when measuring the hydraulic pressure.
Relief pressure kPa (kg/cm2) [psi]

15-9
OIL CONTROL VALVE LINK
COMPONENTS
6709
6709-209
16-2
SST LIST
16-3
SERVICE STANDARDS LIST
BATTERY
CONTROLLER
and represent the positive (red) probe and negative (black) probe of the circuit tester
16-4
16-5
Accelerator Potentio-Meter
Brake Switch (LSB)
Parking Brake Switch (SWPB)

16-6
Material Handling System Switches
Direction Switch
16-7
MOTOR
Drive Motor
Pump Motor
16-8
Power Steering Motor
FRONT AXLE & TRANSMISSION
REAR AXLE
16-9
STEERING
Steering Cylinder
BRAKE
Foot Brake
Brake Pedal
Parking Brake
MATERIAL HANDLING SYSTEM

16-10
MAST
Fork
CYLINDER
Lift Cylinder
Tilt Cylinder
OIL PUMP
16-11
Lifting Speed (V mast)
OIL CONTROL VALVE

16-12
CONNECTOR DRAWING (FOR OTHER THAN U.S.A.)

16-13
16-14
16-15
16-16
16-17
CONNECTOR DRAWING (FOR U.S.A.)

16-18
16-19
16-20
16-21
16-22
CPU BOARD & DC/SD BOARD CONNECTOR DRAWING

(Harness side)
CN101 CN102
CN111 CN112
16-23
CN103 CN104
CN105 CN106
16-24
CN107
MCS-III A CHECK SUB-HARNESS (SST 09240-12240-71)

CONNECTOR DRAWING ON INSPECTION SIDE.
CN101 CN102
CN111 CN112
CN103 CN104
CN105 CN106
CN107
16-28
CONNECTING DIAGRAM (FOR OTHER THAN U.S.A.)
16-26
CONNECTING DIAGRAM (FOR U.S.A.)

16-27
WIRING DIAGRAM (FOR OTHER THAN U.S.A.)

16-28
WIRING DIAGRAM (FOR U.S.A.)

Toyota 5FBE10-18 - Service Manual

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Toyota 5FBE10-18 - Service Manual

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FOREWORD

This manual covers the service procedures of the TOYOTA BATTERY

TOYOTA MOTOR CORPORATION

*: 36 V is provided for UL specification.

HOW TO READ THIS MANUAL

Example of description in pattern B

DISASSEMBLY- INSPECTION - REASSEMBLY Tightening torque unit T = N m (kgf-cm)[ft-lb]

If a place or part be indi-

1 Remove the cover. [Point 1]

2 Remove the bush [Point 2] Operation explained later

3 Remove the gear.

Point operations Explanation of key point for operation with an illustration

How to read components figures (Example)

Matters omitted in this manual

Standard: Values showing allowable range in inspection and adjustment.

LIST OF ABBREVIATIONS AND SYMBOLS

(7) Use genuine Toyota parts for replacement.

3. Grasping the troule state

Measurement result example

Difference in result of measurement with circuit tester

The resistance values of the same semiconductor mea-

voltage in forward direction (v)

Difference in measurement result by measurement range (analog type)

Always use the range described in the repair manual

STANDARD BOLT & NUT TIGHTENING TORQUE

Standard bolt and tightening torques are not indicated.

BOLT STRENGTH TYPE IDENTIFICATION METHOD

1. Identification by bolt shape 2. Identification by part No.

TIGHTENING TORQUE TABLE

(Bolts with seal lock agent coating on threads)

Do not use the precoat bolt as it is in either of the fol-

Method for reuse of precoat bolts

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

WIRE ROPE SUSPENSION ANGLE LIST

RECOMMENDED LUBRICANTS AND CAPACITIES

45S: Refrigerator specification vehicle

1. Chain I Inspect every 8 hours (daily)

9. Accelerator pedal link 1 MP grease

I: Inspection. Repair or replacement if required.

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

1. The display indicates the remaining battery charge

2. When the battery is discharged fully (100 %), the

OVERDISCHARGE ALARM FUNCTION

1. Material handling with traveling becomes impossible.

2. When material handling is attempted, all indicators on

BATTERY COMPARTMENT & MINIMUM WEIGHT REQUIRED

1 Disconnect the battery plug.

2 Remove the battery hood catch.

3 Open the battery hood.

4 Remove the battery stopper.

5 Remove the battery ASSY.

The installation procedure is the reverse of the removal procedure.

As the level gauge is provided on the side surface of

3. Inspection of electrolyte specific gravity

Specific gravity in fully charged state:

*How to use the hydrometer

4. Insulation resistance inspection

Insulation resistance: 1 M or more

* Battery control table

Control Panel ASSY Contactor Panel ASSY

Control panel W/material handling chopper (OPT)

CONTROL PANEL REMOVAL INSTALLATION

1 Disconnect the battery plug.